EFFECT OF CORROSION IN STRUCTURES

By A.SRIKANTH VIHARI 11131D8701

INTRODUCTION

When a metal is attacked by substances around it, it is said to corrode and this process is called corrosion. Corrosion causes deterioration of essential properties in a material. Billions of rupees are lost each year because corrosion and a huge amount of money is spent in prevention of corrosion and tarnishing of metals. Corrosion involves the reaction of a metallic material with its environment and is a natural process in the sense that the metal is attempting to revert to the chemically combined state in which it is almost invariably found in the earths crust. corrosion may be regarded as resulting in a variety of changes in the geometry of structures or components that invariably lead, eventually, to a loss of engineering function e.g. general wastage leading to decrease in section, pitting leading to perforation, cracking leading to fracture.

CORROSION IN STEEL REINFORCED CONCRETES

Corrosion-induced deterioration of reinforced concrete can be modelled in terms of three component steps: Time for corrosion initiation, Ti; Time, subsequent to corrosion initiation, for appearance of a crack on the external concrete surface (crack propagation), Tp; and Time for surface cracks to progress into further damage and develop into spalls, Td, to the point where the functional service life, Tf, is reached. Figure illustrates these schematically as a plot of cumulative damage versus time.

CORROSION REACTIONS:
Some of the anodic and cathode reactions that occur simultaneously on a metal surface in a "corrosion cell" are as follows. A typical anodic oxidation that produces dissolved ionic product, for example for iron metal is: [1] Fe ==> Fe2+ + 2eExamples of cathodic reduces involved in corrosion process are: [2]O2 + 2H2O + 4e- ==> 4OH[3] O2 + 4H+ + 4e- ==> 2H2O [4] 2H+ + 2e- ==> H2

The cathodic reaction represented by Equation [2] exemplifies corrosion in natural environments where corrosion occurs at nearly neutral pH values. Equations [3] and [4] represent corrosion processes taking place in the acidic environments encountered in industrial processes or for the confined volumes (pits, crevices) where the pH can reach acidic values because of hydrolysis reactions such as: [5] Fe2+ + 2H2O ==> Fe (OH)2 + 2H+ This reaction produces H+ ions, the concentration of which can, under certain conditions, become large if the H+ ions cannot readily move out from a confined volume. The overall corrosion reaction is, of course, the sum of the cathodic and anodic partial reactions. For example, for a reaction producing dissolved ions (sum of reactions [1] and [4]): [6] Fe + 2H+ ==> Fe2+ + H2 [7] 2Fe + O2 + 2H2O ==> 2Fe(OH)2

FACTORS ASSOCIATED MAINLY WITH THE METAL

Effective electrode potential of a metal in a solution Over voltage of hydrogen on the metal Chemical and physical homogeneity of the metal surface Inherent ability to form an insoluble protective film

FACTORS WHICH VARY MAINLY WITH THE ENVIRONMENT

Hydrogen-ion concentration (pH) in the solution Influence of oxygen in solution adjacent to the metal Specific nature and concentration of other ions in solution Rate of flow of the solution in contact with the metal Ability of environment to form a protective deposit on the metal Temperature Cyclic stress (corrosion fatigue) Contact between dissimilar metals or other materials as affecting localized corrosion.

TYPES OF CORROSION

Uniform Corrosion Pitting Corrosion Galvanic Corrosion Crevice Corrosion Concentration Cell Corrosion Graphitic Corrosion

1) Uniform Corrosion:

The metal loss is uniform from the surface. Often combined with high-velocity fluid erosion, with or without abrasives. Generally noticed with industrial and hydraulic structures.

2) Pitting Corrosion:

The metal loss is randomly located on the metal surface. Often combined with stagnant fluid or in areas with low fluid velocity, such as water tanks.

3) Galvanic Corrosion:

Occurs when two metals with different electrode potential is connected in a corrosive electrolytic environment. The anodic metal develops deep pits and groves in the surface. This type is noticed on other than reinforcement in structures where different metal fixtures / fittings are used.

4) Crevice Corrosion: Occurs at places with gaskets, bolts and lap joints where crevice exists. Crevice corrosion creates pits similar to pitting corrosion. It is noticed in industrial structures steel structures and hybrid structures. Crevice corrosion is a localized form of corrosion usually associated with a stagnant solution on the microenvironmental level. Such stagnant microenvironments tend to occur in crevices (shielded areas).

5) Concentration Cell Corrosion:

Occurs where the surface is exposed to an electrolytic environment where the concentration of the corrosive fluid or the dissolved oxygen varies. Often combined with stagnant fluid or in areas with low fluid velocity. Dampness periodic water retention with Rcc and steel structures are prone to this type of corrosion. Cast iron loosing iron in salt water or acids. Leaves the graphite in place, resulting in a soft weak metal. As waste water pipes and fixtures are liable for this type of corrosion.

6) Graphitic Corrosion:

REASONS OF CORROSION
The two most common causes of reinforcement corrosion are (i) localized breakdown of the passive film on the steel by chloride ions and (ii) general breakdown of passivity by neutralization of the concrete, predominantly by reaction with atmospheric carbon dioxide. Sound concrete is an ideal environment for steel but the increased use of deicing salts and the increased concentration of carbon dioxide in modern environments principally due to industrial pollution, has resulted in corrosion of the rebar becoming the primary cause of failure of this material. The scale of this problem has reached alarming proportions in various parts of the world.

FOLLOWING ARE THE CONTRIBUTING FACTORS LEADING TO CORROSION: Cracks due to Mechanical Loading
Cracks in concrete formed as a result of tensile loading, shrinkage or other factors can also allow the ingress of the atmosphere and provide a zone from which the carbonation front can develop. If the crack penetrates to the steel, protection can be lost. This is especially so under tensile loading, for deboning of steel and concrete occurs to some extent on each side of the crack, thus removing the alkaline environment and so destroying the protection in the vicinity of the deboning.
o

Stray Currents
o Stray currents, arising for instance from railways, cathodic protection systems, or high voltage power lines, are known to induce corrosion on buried metal structures, leading to severe localized attack. o They may find a low resistance path by flowing through metallic structures buried in the soil (pipelines, tanks, industrial and marine structures). a cathodic reaction (e.g., oxygen reduction or hydrogen evolution) takes place where the current enters the buried structure, while an anodic reaction (e.g., metal dissolution) occurs where the current returns to the original path, through the soil.

Metal loss results at the anodic points, where the current leaves the structure; usually, the attack is extremely localised and can have dramatic consequences especially on pipelines.

Example of stray current from a DC railway line picked up by steel reinforcement in concrete

Corrosion of steel reinforcement due to atmospheric pollution

Most of the times steel reinforcement is exposed to the atmosphere during transportation and storage in the building sites for a long period before their installation in the concrete structures. At any of those stages, steel rebars can be contaminated by chloride ions from sea spray or windblown salt. This fact leads to the formation of corrosion products on their surface.

Fiber optical microscope images after three months at open atmosphere conditions.

Moisture Pathwa

If the surface of the concrete is subject to long-term wetting, the water will eventually reach the level of the reinforcement, either through diffusion through the porous structure of the concrete, or by traveling along cracks in the concrete. Concrete roof decks, by their nature, are meant to be protected from moisture. However, the presence of moisture on roofing systems may result from failure of the roofing membrane, poor detailing of drainage facilities, or lack of maintenance of drainage facilities.

Overwatered leading to shrinkage cracking

Low Concrete Tensile Strength

Concrete with low tensile strength facilitates corrosion damage in two ways. First, the concrete develops tension or shrinkage cracks more easily, admitting moisture and oxygen, and in some cases chlorides, to the level of the reinforcement. Second, the concrete is more susceptible to developing cracks at the point that the reinforcement begins to corrode.

EXAMPLE OF CORROSION:
Bhopal Accident

Bhopal is probably the site of the greatest industrial disaster in history. Between 1977 and 1984, Union Carbide India Limited (UCIL), located within a crowded working class neighbourhood in Bhopal, was licensed by the Madhya Pradesh Government to manufacture phosgene, mono methylamine (MMA), Methyl Iso Cyanate (MIC) and the pesticide Carbaryl, also known as Sevin. The long term effects were made worse by the absence of systems to care for and compensate the victims. Furthermore, safety standards and maintenance procedures at the plant had been deteriorating and ignored for months. A listing of the defects of the MIC unit runs as follows:

Gauges measuring temperature and pressure in the various parts of the unit, including the crucial MIC storage tanks, were so notoriously unreliable that workers ignored early signs of trouble. The refrigeration unit for keeping MIC at low temperatures (and therefore less likely to undergo overheating and expansion should a contaminant enter the tank) had been shut off for some time. The gas scrubber, designed to neutralize any escaping MIC, had been shut off for maintenance. Even had it been operative, post-disaster inquiries revealed, the maximum pressure it could handle was only one-quarter that which was actually reached in the accident. The flare tower, designed to burn off MIC escaping from the scrubber, was also turned off, waiting for replacement of a corroded piece of pipe. The tower, however, was inadequately designed for its task, as it was capable of handling only a quarter of the volume of gas released

PREVENTION METHODS

Keep concrete always dry, so that there is no H2O to form rust. Also aggressive agents cannot easily diffuse into dry concrete. If concrete is always wet, then there is no oxygen to form rust. A polymeric coating is applied to the concrete member to keep out aggressive agents. A polymeric coating is applied to the reinforcing bars to protect them from moisture and aggressive agents. The embedded epoxy-coating on steel bars provide a certain degree of protection to the steel bars and, thereby, delay the initiation of corrosion. These coatings permit movement of moisture to the steel surface but restrict oxygen penetration such that a necessary reactant at cathodic sites is excluded. Stainless steel or cladded stainless steel is used in lieu of conventional black bars.

FLY ASH : Using a Fly Ash concrete with very low permeability, which will delay the arrival of carbonation and chlorides at the level of the steel reinforcement. Fly Ash is a finely divided silica rich powder that, in itself, gives no benefit when added to a concrete mixture, unless it can react with the calcium hydroxide formed in the first few days of hydration Concrete mix design modifications involve such factors as reduced w/c, including use of water reducing admixtures or super plastizers; type of cement; permeability reducing admixtures such as fly ash, silica fume, and blast furnace slag; and corrosion inhibiting admixtures. Structural design aspects of corrosion control involve factors such as configurational (geometrical) considerations that minimize or, if possible, eliminate exposure to corrosives.

Here are following pictures of building showing corroded regions

In this image is clearly shown that the beam and slab of the building are clearly damaged due to the effect of corrosion. The beam was failed due to the non provision of sufficient clear cover.

This image is the perfect example for column failure due to the effect of corrosion.

CONCLUSION

There are a number of ways of assessing on-line corrosion, involving electro chemical measurements or more direct assessments of effective section, but ins pection visual or otherwise, for all systems that may corrode has ramifications for the designer in ensuring that it is possible. In some installations this may involve the incorporation of probes, coupons or test specimens exposed to the same environment as the plant and therefore simulating the corrosion of the latter, but in a form which allows easier assessment of the extent of corrosion.
Finally, but as an integral part of the total design and not as an afterthought, the means of corrosion control, by material modification or by chemical or electrochemical treatment, should be considered with as much care as is put into any other aspect of the design process.

The effects of fabrication methods also should be considered in this context, welded, brazed or soldered joints, where applicable and providing any dissimilar metal contact problems are taken into account, usually providing less risk of crevices than mechanical fastening methods, although whatever method of joining is employed only careful attention to detail can ensure satisfactory performance.

Thank you