Startseite Naturwissenschaften Influences of pre-bending load and corrosion degree of reinforcement on the loading capacity of concrete beams
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Influences of pre-bending load and corrosion degree of reinforcement on the loading capacity of concrete beams

  • The Truyen Tran , Thu Minh Tran , Xuan Tung Nguyen EMAIL logo , Duc Hieu Nguyen , Ba Thanh Vu und Van Nam Vo
Veröffentlicht/Copyright: 22. Juli 2022

Abstract

In this article, experimental studies on the flexural behavior of concrete beams with corroded reinforcement were conducted. The beams were subjected to simultaneous different load levels and immersed in NaCl solution for 30 days with accelerated corrosion. A four-point bending test was subsequently carried out to determine the loading capacity of these beams. Experimental data show that the loading capacity of the beam decreases as the level of preload increases. The mass loss of steel bars in the beams increases as the level of preload increases. The loading capacity and steel mass loss of the beams subjected to 0.8 of failure load of the non-corroded beam decrease by 32.7 and 30.3%, respectively. The numerical investigation was also done to evaluate the loading capacity with various corrosion degrees of steel bars.

1 Introduction

Corrosion of reinforcement is a common phenomenon for reinforced concrete (RC) structures subjected to chloride ion penetration or carbonization, especially in strong aggressive environments such as marine and polluted areas. This phenomenon can cause cracking of the protective concrete layer, reducing the diameter of the reinforcement and the bonding ability between the concrete and the reinforcement. This leads to reduced loading capacity and the service life of the structures. The alkaline environment in concrete creates a thin film that protects the reinforcement inside it. The reinforcement is corroded when this protective film is destroyed. One of the main causes leading to the destruction of the protective film is the penetration of chloride ions from the outside through micro-cracks into the concrete cover [1]. Studies on chloride diffusivity and reinforcement corrosion of concrete and RC structures have been conducted for many decades. Pradhan [2] carried out an experimental study to investigate and compare the corrosion parameters of concrete specimens fabricated from two types of cements including ordinary Portland cement and Portland pozzolana cement. Tran et al. [3] experimentally studied the chloride ingress into concrete under simultaneous compression and chloride exposure. The results showed that the chloride diffusion coefficient of concrete increases as the compressive stress level increases due to the occurrence of micro-cracks. To suppress the growth of cracks and reduce the ability to diffuse chlorine into the concrete, steel fibers were utilized [4]. The results found that the concrete with steel fibers provides a lower chloride diffusion coefficient than conventional concrete in the case of cracked concrete.

Studies using the pull-out test to evaluate the bond characteristics of corroded reinforcements in concrete showed that the bond strength between corroded reinforcements and concrete is reduced with the degree of the reinforcement corrosion [59]. Experimental studies on the effect of long-term corrosion on the characteristics of RC beams were carried out [1013]. The test beams were subjected to three-point bending and placed in the corrosive environment from 26 to 28 years. Nguyen et al. [14] and Tang et al. [15] conducted experimental and numerical investigations on the behavior of RC beams exposed to chloride environment. Al-Kutti et al. [16] and Shen et al. [17] presented experimental and numerical studies on RC beams subjected to simultaneously constant load and chloride exposure. Besides, studies on the influence of corrosion on the residual capacity of pre-stressed concrete beams were also carried out [1820]. In general, the capacity of corroded beams was significantly decreased. Furthermore, numerical and analytical studies were undertaken to predict the corrosion process and the service life of the structure [2127]. The combination of simulation and experiment is commonly used to evaluate the behavior of RC structures [28,29].

In this article, experimental investigations on the influence of reinforcement corrosion on the behavior of RC beams were performed. The test beams were subjected to simultaneous different load levels and immersed in 3% NaCl solution for 30 days with accelerated corrosion. The numerical simulation was also developed to evaluate the loading capacity with various corrosion degrees of steel bars.

2 Experimental program

2.1 Specimen preparation

Twelve RC beams with a cross-section of 100 mm × 100 mm and 500 mm length were cast in this study. The measured compressive strength of concrete is 38.6 MPa at 28 days. Table 1 presents the mixture proportion of this concrete for 1 m3. Two plain round bars with a diameter of 10 mm (D10) were arranged in the bottom fiber of the test beam samples with a protective concrete layer thickness of 30 mm, as shown in Figure 1. The steel bar has a yield strength of 240 MPa and an elastic modulus of 210 GPa. Figure 2 shows the test beams after casting.

Table 1

Mixture proportion for 1 m3 of concrete (unit: kg)

Cement PCB40 Fine aggregate Coarse aggregate Water
480 712 1,046 212
Figure 1 
                  Layout of test beams.
Figure 1

Layout of test beams.

Figure 2 
                  Test beams after fabrication.
Figure 2

Test beams after fabrication.

2.2 Experimental procedures

The experimental steps are briefly described in Figure 3. The test beams were cured in water at ambient temperature for 28 days. Afterward, two beams were tested by a four-point bending test until failure to determine the failure load (P max). Figure 4 presents the four-point bending test to determine the failure load. Subsequently, the ten beams were divided into five pairs and were loaded at 0, 0.2, 0.4, 0.6, and 0.8 of P max. The test beams were denoted according to the load level, including SP0.0, SP0.2, SP0.4, SP0.6, and SP0.8. The “A” and “B” characters followed were used to distinguish the beams in a pair as shown in Table 2. Each pair of beams were loaded utilizing a steel loading frame, as shown in Figure 5. The loading frame consists of steel plates, loading bolts, nuts, and steel supports. The nuts were tightened to transfer the force to the test beams according to the load levels. Figure 6 shows a pair of test beams placed in a steel frame.

Figure 3 
                  Flow chart of the experimental steps.
Figure 3

Flow chart of the experimental steps.

Figure 4 
                  Four-point bending test.
Figure 4

Four-point bending test.

Table 2

Design of test beams

Specimen Load level
SP0.0-A, SP0.0-B 0.0 P max
SP0.2-A, SP0.2-B 0.2 P max
SP0.4-A, SP0.4-B 0.4 P max
SP0.6-A, SP0.6-B 0.6 P max
SP0.8-A, SP0.8-B 0.8 P max
Figure 5 
                  Diagram of the loading frame.
Figure 5

Diagram of the loading frame.

Figure 6 
                  Arrangement for the loaded beam using a steel frame.
Figure 6

Arrangement for the loaded beam using a steel frame.

The rebars inside the beam and the copper plate are connected to the anode and cathode of the power supply using electrical wires, as shown in Figure 7(a). El Maaddawy and Soudki [30] used a current density up to 500 μA/cm2, Han et al. [31] utilized a current density of 1,000 μA/cm2, Al-Sulaimani et al. [32] and Lee et al. [33] applied a current density of 2,000 μA/cm2. However, the higher current density can adversely affect the bond behavior between steel and concrete [34]. Previous studies on accelerated corrosion for RC beams recommended that the current density should not exceed 200 μA/cm2 [30,34,35]. Nonetheless, the lower current density needs a longer time to reach the required corrosion rate. In this study, a current density of 300 μA/cm2 was chosen for the accelerated corrosion test. These loaded beams were soaked in 3% NaCl solution for 1 month, as shown in Figure 7(b). After 30 days of exposure to NaCl solution, the beams with different pre-loaded levels were dried and tested by a four-point bending test until failure to definite the loading capacity. After the bending test, the corroded steel bars of the beams were cleaned of rust and concrete and then weighed. The mass of the corroded bar was compared with the mass of the initial bar to determine the mass loss due to corrosion.

Figure 7 
                  Soak beam in NaCl solution: (a) diagram description of accelerated corrosion test and (b) setup for accelerated corrosion test.
Figure 7

Soak beam in NaCl solution: (a) diagram description of accelerated corrosion test and (b) setup for accelerated corrosion test.

3 Experimental results

3.1 Loading capacity of the beams

The four-point bending tests were carried out to determine the loading capacity of the beams. Table 3 presents the failure load (P max) of two beams with non-corroded reinforcement. The average value of failure load was 27.83 kN. The loading capacity results of beams with corroded reinforcement according to the load level are shown in Table 4 and Figure 8. After 30 days of soaking in 3% NaCl solution, the loading capacity of unloaded beams (i.e., SP0.0-A and -B) decreases by an average of 24.2% compared with non-corroded beams (P max).

Table 3

Failure load of beams without corrosion (unit: kN)

Specimen P max
1 28.00
2 27.66
Average 27.83
Table 4

Loading capacity of beams with corroded reinforcement

Specimen Load level Loading capacity (kN) Average (kN)
SP0.0-A 0 P max 19.96 21.03
SP0.0-B 22.10
SP0.2-A 0.2 P max 20.2 19.58
SP0.2-B 18.95
SP0.4-A 0.4 P max 17.4 17.14
SP0.4-B 16.88
SP0.6-A 0.6 P max 12.9 14.55
SP0.6-B 16.2
SP0.8-A 0.8 P max 15.6 14.15
SP0.8-B 12.7
Figure 8 
                  Loading capacity of beams.
Figure 8

Loading capacity of beams.

It can be seen that in the beams with load levels less than 0.4 P max, the loading capacity decreases slightly compared to the unloaded beams (i.e., SP0.0-A and -B). After that, the loading capacity of the beams decreases as the load level increases. The loading capacity of the beams decreases by an average of 18.5, 30.8, and 32.7% for load levels of 0.4, 0.6, and 0.8 P max, respectively, compared to SP0.0. This is caused by the appearance of micro-cracks in the protective concrete layer when the beam is loaded. For load levels less than 0.4 P max, the beams have a small number of micro-cracks and small crack width leads to slow penetration of chloride into the concrete. When the load level increases, the number of micro-cracks increases and the crack width grows leading to a higher chloride diffusion into the concrete. Then the reinforcements and concrete are corroded faster resulting in a decrease in the loading capacity of RC beams. In the literature, Shen et al. [17] reported that the load capacities of the corroded beams subjected to sustained load with 30 and 50% of the designed loading capacity were decreased by 8.88 and 14.56%, respectively, compared to the corroded beam without preload. In their study, the beams with preload were wrapped with a sponge soaked with 5% NaCl solution for 30 h. Afterward, six wet–dry cycles were applied to those beams with a current density of 200 µA/cm2. Each cycle includes 3-day drying and 4-day wetting. The present work reports a decrease of 18.5, 30.8, and 32.7% for load levels of 0.4, 0.6, and 0.8 P max, respectively, compared to SP0.0 when the beams were immersed in NaCl solution and a current density of 300 µA/cm2 was applied for 30 days. It can be seen that the result in this work is reasonable because the beams were loaded with higher load levels and higher current density than in the study of Shen et al. [17].

Based on experimental data, a linear relationship between the reduction ratio in loading capacity and the load level was observed in this article, as shown in Figure 9. This relationship is given in the following equation:

(1) C i C 0 = 1 . 0008 0 . 4466 P i P max 1 ,

where P max and P i are the failure load of the non-corroded beam and the load level acting on the beam, respectively (kN) (0 < P i < P max), C 0 is the loading capacity of the corroded beam without preload, and C i is the loading capacity of corroded beam corresponding to the load level P i (0 < i < 1).

Figure 9 
                  Relationship between reduction ratio in loading capacity of beams and load level.
Figure 9

Relationship between reduction ratio in loading capacity of beams and load level.

3.2 Mass loss of steel bars

Corroded bars were cleaned and weighed to determine the mass loss due to corrosion. Figure 10 shows four representative beams after testing and removing the protective layer of concrete. An electronic balance was utilized to determine the mass of the corroded steel bars as shown in Figure 11. The steel loss mass is calculated as the initial steel mass minus the steel mass after testing. The mass loss of steel bars after 30 days of soaking concrete beams in 3% NaCl solution is displayed in Table 5 and Figure 12. It is observed that the steel mass loss of the unloaded beams (i.e., SP0.0-A and -B) decreases by an average of 25.2% compared with the initial steel mass. When increasing the load level to 0.4 P max, the average mass loss of corroded steel bars increases slightly to 26.1%. However, when the load level is greater than 0.4 P max, the average mass loss of corroded steel bars increases rapidly with the mass loss of 28.0 and 30.3% for the case of 0.6 and 0.8 P max, respectively. The influence of load level on steel mass loss of RC beams is consistent with the reduction in loading capacity of these beams analyzed above.

Figure 10 
                  Corroded steel bar after the bending test.
Figure 10

Corroded steel bar after the bending test.

Figure 11 
                  Determination of the mass of corroded steel bars.
Figure 11

Determination of the mass of corroded steel bars.

Table 5

Mass loss of corroded steel bars

Specimen Initial steel mass (g) Steel mass after testing (g) Mass loss (g) Mass loss (%) Average (%)
SP0.0-A 560.0 418.3 141.7 25.3 25.3
SP0.0-B 565.0 422.6 142.4 25.2
SP0.2-A 560.0 416.2 143.8 25.7 25.6
SP0.2-B 555.0 413.0 142.0 25.6
SP0.4-A 551.0 410.5 140.5 25.5 26.1
SP0.4-B 553.5 406.3 147.2 26.6
SP0.6-A 556.5 404.6 151.9 27.3 28.0
SP0.6-B 550.5 392.5 158.0 28.7
SP0.8-A 552.5 381.5 171.0 31.0 30.3
SP0.8-B 556.5 392.1 164.4 29.6
Figure 12 
                  Percentage of mass loss of corroded reinforcement.
Figure 12

Percentage of mass loss of corroded reinforcement.

In previous studies, El Maaddawy and Soudki [30] reported a steel mass loss of 7.3% for beams applied to 200 µA/cm2 for 32 days and a steel mass loss of 6.5% for beams applied to 350 µA/cm2 for 15 days. In their study, the beams were only wrapped with wetted burlap sheets during the corrosion process and were not subjected to pre-bending loads. Mancini et al. [35] reported a steel mass loss of 4.77% with the beams applied to 200 µA/cm2 with daily wet–dry cycles for 25 days. In these studies, the influence of the pre-bending load on the beams in the corrosion process was not considered and the beams were not immersed in NaCl solution. From the steel mass loss results of the present study compared to the previous studies, it is shown that the influence of the simultaneous effects of preload and corrosive environment on reinforcement corrosion is significant.

4 Finite element (FE) analysis

4.1 Model properties

A FE software ATENA was utilized to evaluate the loading capacity of the RC beam considering the corrosion of reinforcements. The RC beam was 100 mm × 100 mm cross-section and 500 mm in length. Concrete has a compressive strength of 38.6 MPa at 28 days. Two steel bars have a diameter of 10 mm and a yield strength of 240 MPa which were arranged 20 mm from the bottom fiber of the beams. Figure 13 illustrates the numerical model of RC beam. The beam was modeled with one roller support and one hinged support. One end was restricted against displacements in three directions for the hinged support. Another end was blocked in lateral and vertical directions, and free in the axial direction for the roller support. Two concentrated loads were applied on the beam through two steel plates placed on the top of the beam. The RC beam and steel bar were simulated using eight-node isoparametric brick elements and one-dimensional truss elements with two nodes, respectively, which were available in ATENA. Based on the results from the convergence study, the element size of 25 mm × 25 mm × 25 mm was used to discretize the beam.

Figure 13 
                  FE model.
Figure 13

FE model.

CC3DNonLinCementitious2 material was adopted to simulate the fracture–plastic model of concrete. Figure 14 shows the stress–strain relationship for concrete which was used in this study. In this figure, f t and f c are the tensile and compressive strengths of concrete, ε t and ε c are the corresponding strain at f t and f c , respectively. The behavior for tensile concrete includes tension before and tension after cracking. The linear elastic behavior is employed to depict the characteristics of concrete in tension before cracking. To model the tensile stress–strain relation of concrete after cracking, crack-opening law and fracture energy [36] are used. The model for compressive concrete was developed according to the failure surface of Menetrey and Willam [37]. This model consists of two branches: (i) the ascending branch (i.e., hardening) and (ii) the descending branch (i.e., softening). Material models from CEB-FIP [38] and Van Mier [39] were recommended to describe the ascending and descending branches, respectively. The elastic-perfectly plastic model was utilized for steel bars, as shown in Figure 15.

Figure 14 
                  Stress–strain relationship for concrete.
Figure 14

Stress–strain relationship for concrete.

Figure 15 
                  Stress–strain relationship for steel.
Figure 15

Stress–strain relationship for steel.

Corroded steel bars with a uniform corrosion assumption were used which were also employed in previous studies [18,22,23,27]. The diameter of the corroded steel bar is determined based on the degree of mass loss due to corrosion. In this numerical simulation, steel bars with diameters of 10, 9.7, 9.5, 8.9, and 8.7 mm were used for corrosion degrees of 0, 5, 10, 20, and 25%, respectively. The bond characteristic between rebars and concrete was simulated based on the bond stress–slip relationship which was taken from the CEB-FIB model [38], as shown in Figure 16. This relationship can be defined by the following equations:

(2) τ = τ max s s 1 α if 0 s s 1 ,

(3) τ = τ max if s 1 < s s 2 ,

(4) τ = τ max ( τ max τ f ) s - s 1 s 3 - s 2 if s 2 < s s 3 ,

(5) τ = τ f if s 3 < s ,

where τ and τ max are the bond stress and maximum bond stress, respectively; s 1, s 2, and s 3 are the slips. The values of these parameters are taken for plain round steel in the CEB-FIB model [38].

Figure 16 
                  Bond stress–slip relationship between steel bar and concrete [36].
Figure 16

Bond stress–slip relationship between steel bar and concrete [36].

To verify the FE model, comparisons between experimental data and simulation results were conducted. The test beam was selected as SP0.0-A with 25% reinforcement corrosion. Figure 17 displays a comparison of the load–displacement curve between the FE result and the experimental data. The observation shows that the numerical result matches well with the experimental data. The predicting capacity was 19.1 kN compared to 19.96 kN in the experiment. A comparison of crack distribution between the experiment and FE model is presented in Figure 18. Cracks tend to develop obliquely from the application point of load to the support. It can be seen that the crack growth between the FE model and the experiment is similar.

Figure 17 
                  Comparisons between experimental data and FE model.
Figure 17

Comparisons between experimental data and FE model.

Figure 18 
                  Comparison of crack distribution between experimental and FE model.
Figure 18

Comparison of crack distribution between experimental and FE model.

4.2 Numerical results

Figure 19 presents the load–displacement curve for beam models with different corrosion degrees of reinforcement. The loading capacities of beams with different corrosion degrees of reinforcement are summarized in Table 6. The observation shows that the loading capacity of the RC beam decreases as the corrosion degree increases. Due to the corrosion of the reinforcement, the effective cross-section of the reinforcement in the RC beam is reduced. This leads to a decrease in the loading capacity of the RC beam. Compared to the case of 0% reinforcement corrosion degree, the capacities of the beam reduce to 83 and 72% for 10 and 25% reinforcement corrosion degrees, respectively. A linear relationship is observed between capacity reduction and reinforcement corrosion degree, as shown in Figure 20. This relationship is defined by the following equations:

(6) y = 0 . 022 x + 1 for 0 x 5 ,

(7) y = 0 . 008 x + 0 . 92 for x > 5 ,

where y is the reduction ratio in loading capacity and x is the reinforcement corrosion degree (%).

Figure 19 
                  Numerical results for different reinforcement corrosion degrees.
Figure 19

Numerical results for different reinforcement corrosion degrees.

Table 6

Loading capacity of RC beams based on reinforcement corrosion degree

Corrosion degree (%) Loading capacity (kN)
0 26.5
5 23.5
10 22.0
20 20.2
25 19.1
Figure 20 
                  Reduction ratio of beams.
Figure 20

Reduction ratio of beams.

5 Conclusions

In this article, experimental investigations on the influence of reinforcement corrosion on the behavior of RC beams were performed. The beams were subjected to simultaneous different load levels and immersed in NaCl solution for 30 days with accelerated corrosion. When the load level increases, the number of micro-cracks increases, and the crack width grows leading to a higher chloride diffusion into the concrete. Then the reinforcements are corroded faster resulting in a decrease in the loading capacity of RC beams. Experimental data show that the mass loss of steel bars increases as the level of preload increases. The steel mass loss of SP0.0 and SP0.8 decreases by 25.2 and 30.3% compared with the initial steel mass, respectively. And the loading capacity of the beam decreases as the level of preload increases. Compared to SP0.0, the loading capacity of SP0.4 and SP0.8 decreases by 18.5 and 32.7%, respectively.

A numerical investigation was subsequently carried out to evaluate the loading capacity with various corrosion degrees of steel bars. The observation shows that the loading capacity of the RC beam decreases as the corrosion degree increases. Due to the corrosion of the reinforcement, the effective cross-section of the reinforcement in the RC beam is reduced. Compared to the beam with 0% reinforcement corrosion degree, the capacities of the beam reduce to 83 and 72% for 10 and 25% corrosion degrees, respectively.

Based on experimental results, a linear relationship between the capacity reduction and preload level was observed. From numerical analysis, a linear relationship between the decrease in the capacity of RC beams and the degree of reinforcement corrosion was also detected. However, this study was performed for short concrete beams with only tensile reinforcement. Further studies for larger beams are needed to verify the results of this study.

Acknowledgments

This research is funded by the Vietnam Ministry of Education and Training under-grant number B2022-GHA-05.

  1. Funding information: This research is funded by the Vietnam Ministry of Education and Training under-grant number B2022-GHA-05 to Project No: B2022-GHA-05.

  2. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Conflict of interest: Authors state no conflict of interest.

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Received: 2022-01-27
Revised: 2022-05-19
Accepted: 2022-07-01
Published Online: 2022-07-22

© 2022 The Truyen Tran et al., published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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