Introduction of corrosion :-

Corrosion is the disintegration of an engineered material into its constituent atoms due
to chemical reactions with its surroundings.
Corrosion is an electro-chemical process involving an anode, a cathode and an
electrolyte.
In the most common use of the word, this means electrochemical oxidation
of metals in reaction with an oxidant such as oxygen.
Formation of an oxide of iron due to oxidation of the iron atoms in solid solution is a
well-known example of electrochemical corrosion, commonly known as rusting.
This type of damage typically produces oxide(s) or salt(s) of the original metal.
Corrosion can also occur in materials other than metals, such as ceramics or polymers,
although in this context, the term degradation is more common.
In other words, corrosion is the wearing away of metals due to a chemical reaction.
Many structural alloys corrode merely from exposure to moisture in the air, but the
process can be strongly affected by exposure to certain substances (see below).
Corrosion can be concentrated locally to form a pit or crack, or it can extend across a
wide area more or less uniformly corroding the surface. Because corrosion is a
diffusion controlled process, it occurs on exposed surfaces.
The corrosion resistance of metals and alloys is
a basic property related to the easiness with
which these materials react with a given
environment.
Corrosion is a natural process that seeks to
reduce the binding energy in metals.
The end result of corrosion involves a metal
atom being oxidized, whereby it loses one or
more electrons and leaves the bulk metal.
Pure metals are used in many applications.
Copper, for example, is used to make the wire
which goes inside electrical cables. Copper was
chosen because it can be drawn into long thin
wires very easily (it is ductile) and because it is
a good conductor of electricity.
Pure aluminium can also be used in wiring.
It is also used as a cladding material for
aluminium alloy substrates.

CORROSION OF METAL
CORROSION OF METAL
INTRODUCTION OF CORROSION :-
TYPES OF CORROSION :-
1. DRY CORROSION :- It involves direct attack of dry gases (air+oxygen) on the metal
through chemical reaction. As a result an oxide layer is formed over the surface. This
type of corrosion is not common.
2. WET CORROSION :- It involves direct attacks of aqueous media strong or dilute acid or
alkaline on the metal through Electrochemical Reactions. The moisture & oxygen are
also responsible. This type of corrosion is quite common.
3. FLUID CORROSION GENERAL:- When corrosion is generally confined to metal surface
it is known as general corrosion. It occurs in inform fashion over the entire exposed
surface areas.
4. FLUID CORROSION LOCALIZED:- It is most commonly observed on following four
different locations; Specific Site Corrosion mechanically weak spots or dead spots in
reaction vessel. Stress Induced Corrosion residual internal stress in metal, external
applied stress accelerate the corrosion. Liquid Flow Related Corrosion the driving
force is the tendency of the liquid to dissolve solid or penetrating the metal along the
grain boundries at place of wetting. Chemical Reaction Related Corrosion chemical
reactions such as oxidation & reduction.
5. FLUID CORROSION STRUCTURAL:- Here the strength is reduced on account of
corrosion. This may occur when one component of the alloy is removed or released into
solution. The alloy is removed or released into solution.
6. FLUID CORROSION BIOLOGICAL:- The metabolic action of metal oxides can either
directly or indirectly cause deterioration of a metal.
FACTORS INFLUENCING CORROSION :-
1. TEMPERATURE :- Rise in temperature rate reduces the solubility of oxygen or air. The
released oxygen enhance the corrosion. Increase in temperature induces phase change
which enhance the rate of corrosion. At high temperature organic chemicals are
saturated with water as temperature decreases water gets condensed. Oxygen is needed
for maintaining iron oxide film.
2. VELOCITY :- High velocity of corrosion medium increases corrosion. Corrosion pots
are formed rapidly because chemicals are brought to surface high rate. The corrosion
pots are easily stiffled & carried away by expansion of the new surfaces for corrosion.
3. OTHER FACTORS:- The core of corrosive chemical in distillation column,
evaporation,the concrete can change continuously so difficult to predict the corrosion
rate. the presence of moisture that collects during cooling can turn innocious chemical
in to dangerous corroswes.
techniques :- The techniques presently available for examining RCC
structures for corrosion are as follows:
1.Visual investigation. 2.Weight loss
3.Cover meter. 4.Chloride analysis.
5.Resistivity. 6.Water absorption.
7.Moisture content. 8.Cement content
9.Pit depth. 10.Concrete strength




These tests are designed to check one or more of the factors
leading to corrosion such as-
-Poor quality of concrete.
-Moisture content.
-Reduced Electrical Resistance.
-Poor cover to reinforcement.
-Chlorides.
-Less cement or widely varying cement content.
-Carbonation.
visual :-
Corrosion in reinforcement results in three stages of sign.
1.Cracking along the bars
2.Spalling
3.Disintegration.
Cracks along the bar is the first sign which is likely to be ignored as
these cracks are small in size & discontinuous.However this is the right
time to attend to the defect.
When spalling occurs or cracks widen substantially,the reinforcement
bars are rusted substantially.
Repairs to structures where spalling and disintegration has occurred are
more difficult and expensive.


PREVENTION OF CORROSION IN
REINFORCEMENT
RCC can be protected from corrosion in three ways:-
Seal the surface of the concrete to prevent ingress of chlorides and moisture.
Modify the concrete to reduce its permeability, thus retarding the flow of concrete
moisture and chlorides to reach the reinforcing steel.
Protect the reinforcing bars to reduce the effects of chlorides when they do reach the
steel.
More and more designers are specifying multiple levels of protection for structure that
are subjected to the risk of corrosion. It is common to specify epoxy coated reinforcing
steel & silica fume concrete for post tensioned structures.
Corrosion controlling steps in reinforcement are stated in subsequent sections:-
a) Good concrete practise
b) Latex modified concrete
c) Silica fume concrete
d) Epoxy coated reinforcement
e) Providing membranes and sealers
f) Cathodic protection



Good Concrete Practice
It require following considerations:-
By providing adequate cover to reinforcing steel helps in increasing the time it
takes for the chlorides to reach the steel.
By providing adequate curing (not allowing the concrete to dry without curing in
atleast 7 days) reduces hydration &increases permeability & shrinkage.
Use of water reducing admixtures to give the concrete enough workability so that
workers are able to compact concrete properly with ease.
Maintain a low water cement ratio in concrete.
Consolidate the concrete thoroughly using suitable vibrators .
Use post tensioning to minimize cracking, where appropriate.
Include provision for immediate repair of cracks in the original specifications
assuming that the concrete will crack. Repair or seal the cracks before the new
structure is put into service.
Adoption of good concrete practices may not be enough for the required level of
performance to face the severe exposure conditions. But good concrete practices are
the most critical steps in controlling corrosion and deterioration.

Use of latex modified concrete :-
Latex modified concrete is prepared by adding liquid styrene butadiene latex to
conventional concrete. It contains 15% latex solids by weight of cement, and has a
water cement ratio of 0.35 .
It modifies the pore structure of the concrete and reduces its permeability to a very
low range.
It has been associated with some cracking problems and it should be placed in the
evening or at night to reduce cracking.
Its relative cost is high but performance is good to excellent.
Use of silica fume concrete:-
It is an extremely effective pozzolanic material that reacts with calcium hydroxide
produced in hydrated portland cement paste to form additional cementitious
materials which results in reduction of permeability of the concrete.
Typical silica fume concrete mixtures contain 410 kg of cement per cum, 8% to 10%
silica fume by weight of cement, a water powder ratio less than 0.40.
Adequate plasticiser is provided to produce good workability with 50-200mm
slump.
Performance is good to excellent.
The silica fume concrete has a moderate cost.

Epoxy coated reinforcing bars:-
Pre- cleaned reinforcing steel bars are protected with a coating
of powdered epoxy.
The coating physically blocks chloride ions and the performance
of these bars ranges from poor to excellent depending on
effectiveness of coating.
The relative cost of epoxy coated steel is moderate.










Methods of protection from corrosion:-
Surface treatments:-Applied coatings

Plating, painting, and the application of enamel are the most common anti-
corrosion treatments. They work by providing a barrier of corrosion-resistant material
between the damaging environment and the structural material
Platings usually fail only in small sections, and if the plating is more noble than the
substrate (for example, chromium on steel), a galvanic couple will cause any exposed area
to corrode much more rapidly than an unplated surface would.
For this reason, it is often wise to plate with active metal such as zinc or cadmium.
Painting either by roller or brush is more desirable for tight spaces; spray would be better
for larger coating areas such as steel decks and waterfront applications.
Flexible polyurethane coatings, like Durabak-M26 for example, can provide an anti-
corrosive seal with a highly durable slip resistant membrane.
Painted coatings are relatively easy to apply and have fast drying times although
temperature and humidity may cause dry times to vary.
Cathodic protection
Cathodic protection (CP) is a technique to control the corrosion of a metal
surface by making that surface the cathode of an electrochemical cell. Cathodic
protection systems are most commonly used to protect steel, water, and
fuel pipelines and tanks; steel pier piles, ships, and offshore oil platforms.
Biofilm coatings
A new form of protection has been developed by applying certain species of
bacterial films to the surface of metals in highly corrosive environments. This
process increases the corrosion resistance substantially. Alternatively,
antimicrobial-producing biofilms can be used to inhibit mild steel corrosion
from sulfate reducing bacteria.


Corrosion in non metals
Most ceramic materials are almost entirely immune to corrosion. The
strong chemical bonds that hold them together leave very little free chemical
energy in the structure; they can be thought of as already corroded. When
corrosion does occur, it is almost always a simple dissolution of the material or
chemical reaction, rather than an electrochemical process. A common example
of corrosion protection in ceramics is the lime added to soda-lime glass to
reduce its solubility in water; though it is not nearly as soluble as pure sodium
silicate, normal glass does form sub-microscopic flaws when exposed to
moisture. Due to its brittlenss, such flaws cause a dramatic reduction in the
strength of a glass object during its first few hours at room temperature.

Forms of Corrosion
GENERAL
Identified by uniform formation of corrosion products that causes a even thinning of
the substrate steel
LOCALIZED
Caused by difference in chemical or physical conditions between adjoining sites
BACTERIAL
Caused by the formation of bacteria with an affinity for metals on the surface of the
steel
GALVANIC/DISSIMILAR METAL
Caused when dissimilar metals come in contact, the difference in electrical potential
sets up a corrosion cell or a bimetallic couple
Methods of Corrosion Control
BARRIER PROTECTION
Provided by a protective coating that acts as a barrier between corrosive
elements and the metal substrate
Paint
Powder Coatings
Galvanizing
CATHODIC PROTECTION
Employs protecting one metal by connecting it to another metal that is more
anodic, according to the galvanic series
Impressed Current
Galvanic Sacrificial Anode
Galvanic Zinc Application :- Zinc Metallizing, Zinc-rich Paints, Hot-dip Galvanizing
CORROSION RESISTANT MATERIALS
Materials inherently resistant to corrosion in certain environments
Cathodic Protection
Impressed Current:- External source of direct current power is connected (or impressed)
between the structure to be protected and the ground bed (anode) Ideal impressed
current systems use ground bed material that can discharge large amounts of current and
yet still have a long life expectancy.
Galvanic Sacrificial Anode:- Pieces of an active metal such as magnesium or zinc are
placed in contact with the corrosive environment and are electrically connected to the
structure to be protected . Example: Docked Naval Ships
Galvanic Zinc Application
Zinc Metallizing (plating):- Feeding zinc into a heated gun, where it is melted and
sprayed on a structure or part using combustion gases and/or auxiliary compressed air
Zinc-rich Paints:- Zinc-rich paints contain various amounts of metallic zinc dust and
are applied by brush or spray to properly prepared steel
Hot-dip Galvanizing:- Complete immersion of steel into a kettle/vessel of molten
zinc
Corrosion removal
Often it is possible to chemically remove the products of
corrosion to give a clean surface, but one that may exhibit
artifacts of corrosion such as pitting. For example phosphoric
acid in the form ofnaval jelly is often applied to ferrous tools
or surfaces to remove rust.
Corrosion removal should not be confused
with Electropolishing which removes some layers of the
underlying metal to make a smooth surface. For example
phosphoric acid (again) may be used to electropolish copper
but it does this by removing copper, not the products of
copper corrosion.

PREPARATION OF RCC FOR REPAIR
Preparing Of Rcc Element For Repair Includes Removal Of All Loose Materials,cleaning Of
Deteriorated Area And Removal Of Corrosion From Reinforcement.
Contaminated And Loose Concrete Must Be Removed By Hard Steel Brushing And Washing
Thoroughly Before Undertaking Any Repair Work.
Proper Removal Of Loose Or Contaminated Concrete,rebar Cleaning, And Surface
Preparation Are Crucial For Effective Repair.
Many Repair Failures Are Caused By Improper Performance Of These Operations.
The Following Are The Main Steps To Prepare Reinforced Concrete For The Repair.
Exposing And Undercutting Rebar
Cleaning Reinforcing Steel
Compensating Reinforcement
Edge And Surface Conditioning
Exposing And Undercutting Rebar
The Following Procedure Is Used For Repairs Of Horizontal,vertical,and Over Head
Surfaces.They Are Also Applicable When Removing Concrete By Hydro-
demolition,pneumatic, Or Hydraulic,impact Method.
Various Steps Include:
Remove Loose Or Delaminated Concrete Above Corroded Reinforcing Steel.
Undercut All Exposed Corroded Rebar After The Initial Removals.

UNDERCUTTING EXPOSES THE BLIND SIDE OF THE REBAR FOR CLEANING AND WILL
ALLOW THE REPAIR MATERIAL TO FULLY INCAPSULATE THE REBAR, SECURING THE REPAIR
MATERIAL STRURALLY. PROVIDE AT LEAST 15MM CLEARANCE BETWEEN EXPOSED REBARS
AND THE SURROUNDING CONCRETE OR 15MM LARGER THAN THE LARGEST SIZE OF
AGGREGATE IN THE REPAIR MATERIAL WHICH EVER IS GREATER.
CONTINUE REMOVING CONCRETE ALONG CORRODED BARS UNTIL CORROSION FREE
LOCATION ALONG THE BAR ARE REACHED AND WHERE THE BARS ARE WELL BONDED TO
THE SURROUNDING CONCRETE.
DO NOT DAMAGE THE REBARS BOND TO THE SURROUNDING CONCRETE IF NON
CORRODED REINFORCING STEEL IS EXPOSED DURING THE PREPARATION PROCESS.
UNDERCUT THE REBAR IF THE BOND BETWEEN THE REBAR AND SURROUNDING
CONCRETE IS BROKEN.
SECURE THE LOOSE REINFORCEMENT IN PLACE BY TYING IT TO OTHER SECURED BARS OR
BY OTHER APPROPRIATE METHODS.
CLEANING REINFORCING STEEL
REMOVE ALL HEAVY CORROSION AND SCALE FROM THE BAR TO PROMOTE MAXIMUM
BOND OF THE REPAIR MATERIAL.
IT CAN BE DONE PREFERABLY BY ABRASIVE BLASTING METHOD AS ALREADY EXPLAINED.
A TIGHTLY BONDED WITH LIGHT RUST ON THE SURFACE OF REBAR IS USUALLY NOT
DETRIMENTAL TO BOND.
MANUFACTURERS RECOMMNEDATIONS SHOULD BE FOLLOWED FOR REBAR
PREPARATION IF PROTECTIVE COATING IS TO BE APPLIED TO THE REBAR.
COMPENSATING REINFORCEMENT
IF REINFORCING STEEL HAS LOST SIGNIFICANT CROSS SECTION,A STRUCTURAL ENGINEER
SHOULD BE CONSULTED.
IF REPAIR ARE REQUIRED TO THE REINFORCING STEEL ,THE BAR CAN BE REPLACED
COMPLETELY OR SUPPLEMENTARY BARS CAN BE PLACED OVER THE AFFECTED SECTION.
SUPPLEMENTARY BARS MAY BE MECHANICALLY SPLICED TO OLD BARS OR PLACED PARALLEL
TO OLD BARS APPROXIMATELY 15MM FROM EXISTING BARS. LAP LENGTHS SHALL BE
DETERMINED IN ACCORDANCE WITH LATEST IS SPECIFICATIONS AND OTHER DESIGN
GUIDELINES .
EDGE AND SURFACE CONDITIONING
THE SURFACE CONDITIONING STEPS ARE USED FOR HORIZONTAL, VERTICAL, AND OVERHEAD
SURFACES.
THEY ARE ALSO APPLICABLE TO CONCRETE REMOVAL BY HYDRODEMOLITION AND ELECTRIC,
PNEUMATIC, OR HYDRAULIC IMPACT BREAKERS.
AFTER REMOVING DELAMINATED CONCRETE AND UNDERCUTTING REINFORCING STEEL, REMOVE
ADDITIONAL CONCRETE AS REQUIRED TO PROVIDE THE MINIMUM REQUIRED THICKNESS OF THE
REPAIR MATERIAL.AT EDGE LOCATION, PROVIDE RIGHT ANGLE CUTS TO THE CONCRETE SURFACE
WITH EITHER OF THE FOLLOWING METHODS.
SAW CUT 12MM OR LESS AS REQUIRED.AVOID CUTTING REINFORCING STEEL .
USE POWER EQUIPMENT,SUCH AS HYDRODEMOLITION OR IMPACT BREAKERS. AVOID FEATHER
EDGES.
REPAIR CONFIGURATION SHOULD BE KEPT AS SIMPLE AS POSSIBLE PREFERABLY WITH SQUARED
CORNERS.
REMOVE BOND INHIBITING MATERIALS, SUCH AS DIRT, CONCRETE LAITANCE,AND LOOSE
AGGREGATES BY ABRASIVE BLASTING OR HIGH-PRESSURE WATER BLASTING WITH OR WITHOUT
ABRASIVE. CHECK, THE CONCRETE SURFACE AFTER CLEANING TO ENSURE THAT THEY ARE FREE
FORM LOOSE AGGREGATES AND DELAMINATIONS.


REPAIR OF CORRODED RCC ELEMENTS
REPAIR OF CORRODED REINFORCEMENT INCLUDES FOLLOWING MAIN STEPS.
CHIP OFF ALL LOOSE AND CRACKED CONCRETE IN RCC ELEMENT.
REMOVE CONCRETE IN COVER COMPLETELY TO EXPOSE CORRODED REINFORCEMENT.
REMOVE ALL LOOSE AND DETERIORATED CONCRETE BY WIRE BRUSH.
CLEAN THE REINFORCEMENT THOROUGHLY TO REMOVE ALL RUST OF CORRODED STEEL
BY SAND BLASTING OR CHEMICAL WASH.
WASH AND SATURATE ALL CAVITIES IN ADJOINING CONCRETE WITH CLEAN WATER AND
REMOVE ALL FREE WATER BEFORE PLACING REPAIR MORTAR.
FILL ALL CRACKS WITH EPOXY RESINS AND APPLY BOND COAT JUST PRIOR TO PLACING
PATCH REPAIR MORTAR OR CONCRTE.
APPLY PATCH REPAIR MORTAR OR CONCRETE OR GROUT ON THE DAMP CAVITY
SURFACE.
IN CASE OF LOSS OF STEEL SECTION,ADDITIONAL STEEL REINFORCEMENT MAY BE TIED TO
THE EXISTING BARS PRIOR TO APPLICATION OF BOND COAT.
FILL THE CAVITY WITH REPAIR MORTAR OR CONCRETE AND CONSOLIDATE THOROUGHLY
WITH ROD AND MALLET OR VIBRATION.
ALTERNATIVELY FILL,PREPACKED AGGREGATE CONCRETE IN THE CAVITIES AFTER
APPLYING BOND COAT ANAD FINISH WITH PRESSURE GROUTING WITH REPAIR MORTAR
APPLY A PROTECTIVE COATING ON THE FINISHED SURFACE OF THE REPAIRED ELEMENT


CORROSION DUE TO DAMPNESS
CORROSION DUE TO
WATER AND DUE TO AGE