®@ BEKAERT Durability of steel fibre concrete THE CONSTRUCTIVE IDEAone DURABILITY OF STEEL FIBER CONCRETE The concrete The durability of concrete under normal conditions of use, largely depends on its density. Processes such as carbonation, penetration of chloride ions and sulphate attack are in direct proportion to the permeability of the cement matrix. The addition of Dramix® steel fibers, in accordance with recommended methods, does not decrease the density of the concrete and thus does not increase the penetration of aggressive substances. HV (kg/mm?) 0 2 40 60 80 100 120 D (micrometer) The steel fibers Alkaline protection Much free lime (calcium hydroxide) is formed during the hydration of cement grains and the concrete obtains a pH value of 12 and more. At this pH value, a microscopic oxide film is created on the steel surface. This film has a passivating action, which means that it protects against rust. When the pH value drops to about 8 to 9, this protective environment is lost and if water and oxygen are present, the steel can corrode. The locally lower compaction of cement grains around materials added to the cement paste such as aggregates, steel fibers and conventional reinforcement, causes a transition zone to be formed around these materials as the cement hydrates. This layer, which has a thickness of about 50 micrometers, has less strength than the cement matrix and largely consists of calcium hydroxide (fig. 1). As is demonstrated below, the presence of this large supply of lime around the steel fibers turns out to be an explanation for the good corrosion resistance of the steel fiber concrete. The small diameter fibers, with their large surface area to volume ratio, are more effectively screened by the lime rich layer than the large diameter bars used in conventionally reinforced concrete (9). Fig. 1 Effect of the distance D to the fiber surface and the water-cement factor on compression strength Wiekers microhardness) (1)Id experiences Carbonation Carbonation of concrete is a natural process in the course of which the carbon dioxide in the air causes the concrete to gradually become less alkalinic. The free lime is converted into calcium carbonate and the pH value drops. Carbonation starts at the conerete surface and continues inwards as long as there is enough carbon dioxide available. Carbonation penetration rate is determined by the permeability of the concrete and decreases with time, which means that the process is self-decelerating ‘At a pH value of 8 to 9, the passivating layer on the steel can be broken and humidity would be expected to corrode the steel fiber. Durability of steel fiber concrete The increase in the volume due to corrosion products from a corroded fiber is not sufficient to split the thin concrete coating. Photo 1 shows the corrosion of Dramix® ZC fibers close to the surface as a result of carbonation after 12 years of outdoor exposure. Even this corrosion can be avoided by using Dramix’ ZX fibers, which are provided with a protective zinc layer. Dramix* 20 Dramix* ZX (zinccoated) Photo 1: Surface condition of Dramix*-fiber concrete after 12 years of outdoor exposure in an industrial environment In practice, it has been found that the carbonation front is stopped as it reaches the steel fiber by the large supply of the lime around the fiber. This fiber may lose its protective passivating layer in the longer term, but the fibers located deeper remain safe. It has been established by experiment that in the long term, steel fiber corrosion is limited to a depth of some five millimeters in the case of high quality concrete (2)PM make krsieeeci cs Field experiences Chlorides: Chloride ions can penetrate into concrete that 's exposed to the action of sea water, sea air or deicing salts. If oxygen is present, these free chioride ions weaken the passivating surface of steel reinforcement, which results in either surface corrosion or pitting corrosicn, It has been estabished that steel fibers with a markedly rough surface (Photo 2a) are noticeably more susceptible to pitling corrosion than fibers made from drawn steel wire (Photo 2b) (3). Corrosion by chloride ions, however, is slowed down by the presence of the lime-rich enveloping layer around the steel fiber. This was shown by potential measurements (4), a drop in voltage pointing to the presence of corrosion cells on the steel surface, Pnoto 2: Corrosion teste in sal atmosphore im eocordence with NF X41-002 on fibor concrete precracked 10 0.4 « 0.5 mi. 2b. Surface corrosion of Dramixe ZC Fig. 2 shows that the chloride ions are far less active in sieel fiber concrete than in reintorced conorete. This difference in behavior is also confirmed by accelerated tests in a simulated marine ‘environment (5). No corrosion was etablished, although steel fibers by themselves did not significantly siow down the penetration of chloride ions into concrete. Fig. 3 snows thal the critical limit of 0.4% chloride was exceeded considerably. & 8 & Electiode Potential Vin.V +100 oO 2 a 16 o%cacl? 200 300 + 400 500 +600 a) ays +100 oO * b too] ov Cac’ sab 300 ane =o" a% Gace? ~ =500 + 600 1 37 1 8 OO days Fig. 2: Decrease in potential by adding 2% CaCF to the concrete, mezaured with respect to a. steel fiber b. @ reinforeing barTests in the splashing zone ot sea waves, over a period of five years (6) have shown that corrosion of reinforcing bars, embedded in steel fiber concrete beams, is scroened off by the presonce of the steel fibers. (Fig. 4) Here again, the best results are obtained with fibers of drawn wire, Chloride content 184 4 124 104 oe 064 os depth in concrete (mm) Fig. 3: Chloride penetration in mass percent with respect to cement, atter 300 cycles in sea water, Steel fiber concrete has also been throughly tested in a cracked condition in atmospheres saturated with chloride ions and in chloride free environments (7), (8). The results (Fig. 5) show that, aftor 650 cycles of alternating exposure to sea water, there is no loss. of bending strength if the crack width is smaller than 0.25 mm. Surface area of corrosion (%) 507 40+ 307 20+ 107 years Fig. 4: Evolution of percentage corroded surface of 10 mm diameter bar reinforcement with 30 mm concrete coating, after sea coast exposure with concrete. 2. without steel fibers. b. with sheet-stee! fibers ©. with drawn-wiro fibors modulus of rupture (Nimm") Y_average crack width (mm) 0 1234567 8 Fig. 5: Bending strength of precracked liber concrete atter 650 cycles in sea water, as a function of average crack width for: 14. Dramix’ stoe! fibers 1b. meli-extract steel fibersPokies General conclusions Steel fibers close to the exposed concrete surface can show signs of corrosion due to carbonation of the surrounding concrete, but there is no evidence of damage caused by concrete spalling and accelerated penetration of the carbonation front. If this corrosion is inconveniently detrimental to the aesthetics of the concrete surface, such as in the case of prefabricated concrete elements, preference should be given to the use of zinc- coated Dramix® fibers. Steel wire fibers can restrict the penetration of agaressive substances by reducing cracking in the concrete. There is no danger of damage, if crack widths are limited to 0.25 mm. Here again, zinc-coated Dramix® fibers are superior. But above all, it is important to always take the known precautionary measures for: - good concrete quality - good density - good finishingPM eb ccki sua) Literature (1) Wei S., Mandel JA, Said S., “Study of the Interface Strength in Steel Fiber-Reinforced Cement-based Composites’ ‘American Concrete Institute Journal, July-August 1986, pp. 597-605. (2) Kern B., Schorn H. 23 Jahre alter Stahifaserbeton’, Beton- und Stahtbetonbau, V 86, September 1991, pp. 205-208. (3) Dubois F Nouguier H. “Durability of steel fibrous concrete used for the manufacture of containers for nuclear waste ‘Storage" International Conference on Recent Developments in Fiber Reinforced cements and Concretes, Cardi, 18-20 September, 1989, pp. 573-581. (4) Janotka 1, KrajeL., Konios K., Fitalova D,, “Chloride corrosion of steel fiber reinforcement in cement montar ~. The international Journal of Cement Composites and Lightweight Concrete’, Vol 11, Nr. 4, November 1989, pp. 221-228. (5) Mangat PS., Gurusamy K., Rilem Symposium on Developments in Fiver Reinforced Cement Concrete, Sheffield, 1986, Vol 2, Paper 7.9 (6) Kobayashi K., Hoshino t., Tsuji K, “Etlect of stee! fiber reinforced concrete on the corrasion behavior of reinforcing steel ‘embedded in concrete members exposed fo marine environments” (in Japanese) Proceedings, Japan Socity of civil Engineors (Tokyo) V 12, nr 414, pp. 195:208. (7) Hannant O., Edgington J, Durabilty of stee! fiber concrete’, Proceeding, AILEM Symposium on Fiber reinforced cement and concrete, Vol 1, September 1975, pp. 159-169. (8) Mangat PS, Gurusamy K, “Permissible crack widths in steel fiber reinforced marine concrete’, Materials and Stuctures, 119, 1987 (20) pp. 338-347. (9) Mangat PS,, Gurusamy K., “Corrosion resistance of steel fibers in concrete under marine exposure’, Cement and Concrete reseach. Vol. 18, pp. 44-54, 1988.rue na gteSe meron hen our tence gin orang ss da eit acarsr= Dramix® THE CONSTAUOTIVE IDEA