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1. Historical Perspective, Definitions 2 Deterioration 2. D t i ti Mechanism M h i 3. Design for Durability 4. Good Detailing practice from Durability Considerations
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Untill about 30 years ago, durability was not seen as a serious issue for concrete. Durability became an issue only when following problems were noted all over the world :
1. Very serious deterioration of bridge decks in USA, UK and all other countries due to corrosion of reinforcement, due to use of de-icing salt in bridge decks in winter.
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2. Major deterioration in problems in the Middle East due to chloride induced corrosion in a particularly aggressive environment.
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WHAT IS DURABILITY ? Durability of concrete is its ability to resist weathering action, chemical attack, abrasion or any process of deterioration. The cause may reside inside the concrete itself, or be present in the service environment to which the concrete structure is exposed.
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WHY DURABILITY CONSIDERATIONS ARE IMPORTANT FOR CONCRETE ?
Concrete property changes with time.
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Durability Requirements :
Fulfilment of the requirements of structural t t l safety f t and d serviceability, i bilit within the planned use and the foreseeable actions, without unforeseen expenditure on maintenance and repair.
It is no longer sufficient for the structure to have only Strength. The structure shall last also. So far the practice had been to provide a few deemed to satisfy clauses in the code to ensure durability (e,g. On minimum cover, crack width control, maximum spacing of rebars, minimum concrete grade, minimum cement content, maximum w/c ratio etc.)
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1. DEEMED TO SATISFY CLAUSE SUFFERS FROM FOLLOWING :
Fails to acknowledge that structures deteriorate progressively. p g y
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The LS code has given more importance to durability, in line with the present international practices. The structure has to be designed for durability. Durability is covered exclusively in a separate chapter now (section 14). Classification of Service Environment Four classes defined now as against Two earlier. Design Service life has been accounted for in the provisions of durability. Additional provisions for specific mechanism of deterioration added.
Takes limited account of impact of conceptual & detailed design, construction quality and methods. Has limited flexibility.
2. The new code has defined the end of service life, which demands that structure must be designed for durability.
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HISTORICAL PERSPECTIVE
SECTION 14 : DURABILITY PROVISIONS CONTENT OF PRESENTATION 1. Historical Perspective, Definitions 2 Deterioration 2. D t i ti Mechanism M h i 3. Design for Durability 4. Good Detailing practice from Durability Considerations
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Concrete Deterioration Mechanism
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Alkali - Aggregate Reaction Acid Attack Chloride Sulphate Attack CO2 Carbonation Chlorides
1. Since the maximum damage caused in RCC structures worldwide is primarily due to corrosion of reinforcement, the environmental classification in IRC code is based on specific mechanism of duration (i,e. corrosion only). 2. However, relative importance of the various mechanism of deterioration will vary from region to region.
Depassivation
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DETERIORATION MECHANISM The deterioration process can be divided into two phases :
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3. Most of the reactions in concrete, which causes deterioration are expansion producing and presence of water or moisture is required required. 4. For ensuring durability, It is therefore important that ingress of moisture in concrete is restricted to the extent possible.
During the initiation phase no weakening of the concrete or of the function of the structure occurs. During the propagation phase active deteriorations proceeds rapidly and in many cases with acceleration.
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1. A durable concrete structure has a long initiation phase and a slow propagation p p g phase. 2. The ideal situation by design of new structure is if the initiation phase goes upto say 50 years !
Limit t of acceptable damage
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Concrete Deterioration Mechanism
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Chemical Deterioration
There is need to precisely define the condition which can be treated as end of service life. This can be either in the form of % depassivation or surface cracking or spalling of concrete cover.
Alkali - Aggregate Reaction Acid Attack Chloride Sulphate Attack CO2 Carbonation Chlorides
Depassivation
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Effects of Physical Deterioration :
ABRASION / EROSION / CAVITATION :
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ABRASION / EROSION / CAVITATION :
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GALVANISATION / EPOXY COATINGS IN REBARS SHALL BE ABRASION RESISTANT SO THAT THERE ARE NO DAMAGE CAUSED DURING HANDLING / PLACEMENT. COATINGS IN PRESTRESSING STEEL SHALL ALSO BE ABRASION RESISTANT. ABRASION RESISTANCE IS ALSO A REQUIREMENT FOR THE SHEATHING DUCTS BEING USED.
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Effects of Physical Deterioration :
FROST ATTACK :
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FROST ATTACK .contd. 4. With the addition of an air entrainment admixture, concrete is highly resistant to freezing and thawing.
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1. Capillary p y p pore water in concrete expands p by y 9% after freezing, and produces strong pressure which causes failure, rupture and scaling. 2. Saturation of water is formulated due to repeated freezing and thawing. When it reaches the critical saturation, concrete will be destroyed by freezing. 3. The effective way to prevent freezing and thawing destruction is to add chemical air-entraining agent.
5. During freezing, the water displaced by ice formation in the paste is accommodated so that it is not disruptive; the microscopic air bubbles in the paste provide chambers for the water to enter and thus relieve the hydraullic pressure generated.
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FROST ATTACK .contd.
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6. Concrete with a low water-cement ratio (0.40 or lower) is more durable than concrete with a high water-cement ratio (0.50 or higher). 7. Air-entrained concrete with a low watercement ratio and an air content of 5 to 8% will withstand a great number of cycles of freezing and thawing without distress.
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Concrete Deterioration Mechanism
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Effects of Chemical Deterioration :
ALKALI AGGREGATE REACTION (AAR) :
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Chemical Deterioration
CERTAIN CONSTITUENTS IN AGGREGATES CAN REACT HARMFULLY WITH ALKALI HYDROXIDES IN CONCRETE CAUSING SIGNIFICANT EXPANSIONS. THERE ARE THREE FORMS OF THIS REACTION: 1. ALKALI SILICA REACTION (ASR) 2. ALKALI CARBONATE REACTION (ACR) 3. DELAYED ENTRINGITE FORMATION (DEF)
Alkali - Aggregate Reaction Acid Attack Chloride Sulphate Attack CO2 Carbonation Chlorides
Depassivation
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Effects of Chemical Deterioration : AAR
ALKALI SILICA REACTION (ASR):
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ASR is chemical reaction between alkali in cement and silica in aggregates. aggregates Alkali is sodium or potassium A gel is formed and expansion takes place in presence of moisture, which comes from rain water. Concrete forms surface cracks called map cracking Deterioration is caused by spalling.
The reaction can be visualized as a two-step process: Alkali hydroxide + reactive silica gel alkali-silica gel Alkali-silica gel + moisture expansion The reaction has great affinity for moisture
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Effects of Chemical Deterioration : AAR CONTROL OF ASR:
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USE OF LOW ALKALI PORTLAND CEMENT (LESS THAN 0.6% EQUIVALENT Na2O) WHEN ALKALI SILICA REACTIVE CONSTITUENTS ARE SUSPECTED TO BE PRESENT IN THE AGGREGATE. IF LOW ALKALI CEMENT IS NOT AVAILABLE, THE TOTAL ALKALI CONTENT CAN BE REDUCED BY REPLACING A PART OF HIGH ALKALI CEMENT WITH SUPPLEMENTARY CEMENTITIOUS MATERIALS SUCH AS FLY ASH, GROUND BLAST FURNACE SLAG AND SILICA FUME, OR USE BLENDED CEMENT.
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Utilization of silica fume, fly ash, and blast furnace slag as partial replacement of cement will reduce the expansion.
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Effects of Chemical Deterioration : AAR ALKALI CARBONATE REACTION (ACR):
THE AGGREGATES [DOLOMITE - CALCIUM MAGNE-SIUM CARBONATE] HAVE SPECIFIC
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Effects of Chemical Deterioration : AAR
ALKALI CARBONATE REACTION (ACR): ACR IS A CHEMICAL REACTION BETWEEN
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HYDROXYL IONS ASSOCIATED WITH THE ALKALIS, SODIUM AND POTASSIUM IN THE CEMENT AND CERTAIN DOLOMITIC TEXTURES IN THE AGGREGATE RESULTING IN EXPANSION AND EVENTUALLY CRACKING OF THE HARDENED CONCRETE. (ACR is not as widespread as ASR)
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Effects of Chemical Deterioration : ACID ATTACK
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Effects of Chemical Deterioration : Sulphate Attack Sulfate attack can be external or internal.
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Concrete is susceptible p to acid attack because of its alkaline nature. The components of the cement paste breaks down during contact with acids. Sulphuric acid is very damaging to concrete as it combines an acid attack and a sulfate attack. External: due to penetration of sulfates in solution, in groundwater for example, into the concrete from outside. Internal: due to a soluble source being incorporated into the concrete at the time of mixing, (e,g. gypsum in the aggregate, for example).
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Effects of Chemical Deterioration :
DELAYED ENTRINGITE FORMATION
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SPECIAL TYPE OF INTERNAL SULPHATE ATTACK IS CALLED DELAYED ENTRINGITE FORMATION. THE RELATED EXPANSION PRODUCES CRACKING, SPALLING & STRENGTH LOSS, SINCE IT OCCURS IN HARDENED CONCRETE. ITS DAMAGING EFFECT IS RELATED TO INTERNAL SULPHATE SOURCE
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Concrete Deterioration Mechanism
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Chemical Deterioration
Alkali - Aggregate Reaction Acid Attack Chloride Sulphate Attack CO2 Carbonation Chlorides
Corrosion occurs due to de-passivation of iron-oxide layer alkaline environment surrounding the reinforcement.
Depassivation
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1. Passivity can carbonation. be destroyed by chlorides
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Chlorine ions penetrate to the surface of reinforcing bars from the protective layer,destroy passive film, and change bars from passive state into active state.
2. Once the passivity of steel has been eroded, corrosion yg will continue if there is sufficient moisture and oxygen present at the reinforcement. 3. Corrosion requires both water and oxygen. When concrete is wet, oxygen penetration is inhibited In very dry conditions, where oxygen levels are sufficient, moisture levels are low. 4. The greatest risk of corrosion is therefore in members subjected to cyclic wetting and drying.
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Carbonation :
1. Atmospheric CO2 is converted to carbonic acid (H2CO3) in the presence of moisture, which attacks hydrated cement paste; t this thi is i called ll d carbonation. b ti 2. Carbonation lowers the pH value of concrete and reduces the protection to steel by the alkalinity of the surrounding medium. 3. Rate of Carbonation depends upon the concrete grade, relative humidity & integration of concrete in cover zone
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SECTION 14 : DURABILITY PROVISIONS CONTENT OF PRESENTATION 1. Historical Perspective, Definitions 2 D 2. Deterioration t i ti Mechanism M h i and d Factors F t influencing Durability 3. Design for Durability 4. Good Detailing practice from Durability Considerations
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1. The first step is to establish the aggressiveness of the service environment (exposure conditions). In deciding the appropriate class of service environment, the following factors are to be taken into account (fib, 2009):
a. The general environmental conditions of the area in which the structure is situated,
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b. The specific location and orientation of the concrete surface being considered and its exposure to prevailing winds, rainfall etc., c. Localised conditions such as surface ponding, exposure to surface runoff and spray, aggressive agents, regular wetting, condensation etc.
2. To select the type of structure suitable for the chosen service environment. 3. To select the appropriate materials, mix proportions, workmanship, design and detailing, including minimum cover to steel
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This is in increasing order of likelihood of chloride-induced corrosion and carbonation - induced corrosion, depending
on the chances of carbonation and ingress of chloride ions from outside.
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Moderate category g y is for situations where the chances of carbonation are insignificant because the pores of concrete are either saturated or dry. No ingress of chloride from external sources is anticipated. Inadequate workmanship can lead to corrosion of steel. Provision is also made against attack by other deleterious chemical agents, which are facilitated by the presence of moisture.
1. Severe category is for situations, where presence of moisture (wet, rarely dry) and some carbonation under humid conditions can lead to corrosion of steel. 2. Wet, rarely dry includes concrete surfaces subject to long term water contact and many foundations. Concrete exposed to coastal environment can have access to chloride ions increasing the risk of chloride-induced corrosion.
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3. Concrete components exposed to industrial waters t containing t i i chloride hl id will ill be b included i l d d in i this thi category. 4. In spite of presence of significant amount of chloride ions in sea water, risk of corrosion in concrete completely submerged in sea water below mid-tide level is comparatively less because of paucity of oxygen.
1. When the relative humidity is between 50 to 70 percent, the chances of carbonation are very high. Exposure to air-borne chloride ions in marine environment add significantly to the risk of chloride-induced corrosion. 2. Such exposure conditions are termed very severe. Saturated concrete subjected to cyclic freezing and thawing is prone to effects of expansion due to formation of ice, leading to spalling. Such conditions are anticipated in few areas in the colder regions of the country.
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1 Extreme 1. Extreme category is for conditions conditions, where the risk of corrosion of steel and sulphate attack are the highest in concrete exposed to tidal, splash and spray zones in sea, because of accumulation of salts in the pores and accompanied by damage due to wave action.
2. Concrete in direct contact with aggressive subsoil/ground water can lead to severe attack to concrete in foundations, without being accessible to periodic inspection and maintenance. 3. If harmful effluents from nearby chemical industries are discharged into the water body, where the bridge is situated, it poses serious threat to the durability of concrete. Cyclic wet and dry conditions allow accumulation and build up of deleterious agencies.
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Cover can be reduced by opting for HPC (M30 to M90) In case of blended cement. Reinft. has secondary role in PCC
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1. The values of minimum strength grade in Table 14.2 are those which can be generally expected with the corresponding water cement ratio and with the cements or binders available in India. 2. So, the minimum strength grade specified is an indirect control on the durability parameters.
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PART 4 : DURABILITY PROVISIONS CONTENT OF PRESENTATION 1. Historical Perspective, Definitions 2 D 2. Deterioration t i ti Mechanism M h i and d Factors F t influencing Durability 3. Design for Durability 4. Good Detailing practice from Durability Considerations
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2. Geometry, Size & Shape of Structure (to promote good drainage) 3. Drainage, Detailing for better Drainage 4. Reinforcement Detailing 5. Use of Controlled Permeability Formwork (CPF) 6. Protective Coatings in Concrete 7. Choice of Rebar Coating 8. Corrosion protection of Prestressing Steel
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Drainage : Avoid Horizontal Surface in Substructure Detail to promote quick run-off (e,g top of pier cap to be sloped outside)
Poor Drainage : Severe distress due to corrosion induced by defective expansion joint detail
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Reduced W/C of 0.20 - 0.25 from Bulk W/C of 0.35, In another case, reduced w/c to- 0.40 / 0.35 from 0.50 bulk.
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2. With the advancement in the polymer technology, materials are available which can be used as protective coatings in concrete. 3. Some of the polymers available are Epoxy resin, Polyurethane resin, Acrylic resin, Polyester resin, silicone resin, silane / siloxane acrylic blend primer with a pigmented acrylic top coat.. 4. Suitability of the coating system and cost are important factors in deciding about coatings.
To protect products stored or processed indirect contact with the concrete from contamination caused by dust from the substrate. To improve its appearance, case of maintenance.
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As per MORTH Guideline issued in Jan-2000, for regions within 15 Km radius of the coast, FBEC bars shall be used for Bridges.
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Protection Levels for pt-tendons based on aggressivity / exposure vs. structural protection layers
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THANK YOU
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