Durability

IRC:112-2011
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SECTION 14 : DURABILITY PROVISIONS CONTENT OF PRESENTATION
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NEW UNIFIED CONCRETE CODE Limit State Version (IRC:112-2011)

SECTION 14 : DURABILITY PROVISIONS ALOK BHOWMICK
MANAGING DIRECTOR, B & S ENGINEERING CONSULTANTS PVT. LTD. 315-316, VISHAL CHAMBERS, SECTOR 18, NOIDA U.P
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
IRC:112-2011
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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IRC:112-2011
SECTION 14 : DURABILITY PROVISIONS
HISTORICAL PERSPECTIVE
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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.
3. Severe cracking in structures in many countries resulting from alkali-silica reaction
Deterioration in Bridges from durability reasons
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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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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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Factors affecting Durability

Service Environment Detailing (Cover, (Cover Shape & Size) Construction Method (Workmanship) Type & Quality of Materials used Cement Content & W/C ratio Repair & Maintenance
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DETERIORATION MECHANISM
Concrete Deterioration Mechanism
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Most serious form of degradation of Concrete
Mechanical & Physical Deterioration
Chemical / Biological Deterioration
Reinforcement / Prestressing Steel Corrosion
Abrasion Erosion Plastic Shrinkage
Frost Attack Impact Thermal Effects
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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WHAT IS DESIGN SERVICE LIFE OF A STRUCTURE ?

The assumed period for which a structure is to be used for its intended purposes with anticipatory maintenance, but without major repair being necessary.
What is the end of Service Life ?
(Not defined properly in IRC:112-2011)
DESIGN SERVICE LIFE
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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.
Depassivation
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Effects of Physical Deterioration :
ABRASION / EROSION / CAVITATION :
ABRASION / EROSION / CAVITATION :
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RESISTANCE TO ABRASION CAN BE OBTAINED BY :

USING HIGH STRENGTH CONCRETE USING ABRASION RESISTANT AGGREGATES GOOD CURING
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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.
Abrasion Damage in Concrete
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Effects of Physical Deterioration :
FROST ATTACK :
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.
Freeze & Thaw Effect
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Effects of Chemical Deterioration :
ALKALI AGGREGATE REACTION (AAR) :
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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)
Depassivation
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Effects of Chemical Deterioration : AAR
ALKALI SILICA REACTION (ASR):
DETERIORATION MECHANISM Mechanism :
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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.
Alkali Silica Reaction
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Utilization of silica fume, fly ash, and blast furnace slag as partial replacement of cement will reduce the expansion.
Photographs showing repair of Bridges affected by AlkaliAlkaliSilica Reactions
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Effects of Chemical Deterioration : AAR ALKALI CARBONATE REACTION (ACR):
THE AGGREGATES [DOLOMITE - CALCIUM MAGNE-SIUM CARBONATE] HAVE SPECIFIC
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)
COMPOSITION THAT IS NOT VERY COMMON.
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Effects of Chemical Deterioration : ACID ATTACK
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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Effects of Chemical Deterioration : Sulphate Attack

External Sulfate attack is possibly the most common and widespread form of chemical attack on concrete. In case soluble sulphates is >0.1% in soil, it will have detrimental affect on concrete concrete. More than 0 0.5% 5% is very dangerous. Damage caused by sulfate attack normally occurs as cracking, crumbling and scaling of the concrete. In addition to physical deterioration, sulfate attack may also destroy the binding capability of the cement, thus affecting the mechanical properties of the concrete (strength, elastic modulus).

Sulfate attack occurs as a chemical reaction of sulfate ions (aggressive substance) with the aluminate component of the hardened concrete (reactive substance). Sulfate attack may also occur as a physical attack on concrete due to the crystallization of sulfate salts within the cement matrix. Regions of concrete structures experiencing sulfate attack normally display a characteristic whitish appearance.
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Damage is usually initiated in areas most susceptible to the ingress of contaminants, such as corners and edges g of concrete elements. As the attack progresses, extensive cracking and spalling of the concrete may occur.
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Corrosion occurs due to de-passivation of iron-oxide layer alkaline environment surrounding the reinforcement.
Depassivation
Corrosion Most serious form of deterioration in Concrete
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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
Cracking De-lamination Spalling of cover
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CORROSION PROTECTION MECHANISM & METHODS
Prevent entry at concrete surface.
If penetrates concrete surface, prevent reaching the reinforcement
Graph showing variation of Carbonation Depth with Time
If reaches reinft., control corrosion Best is to avoid reactive substance itself !
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IRC:112-2011
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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DESIGN FOR DURABILITY
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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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4. There are four categories : Moderate, Severe, Very y Severe and Extreme;
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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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Not Sea Water !!
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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Clear cover to any reinft.
Example of a structure in Extreme climatic condition
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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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DESIGN FOR DURABILITY Adjustment for other Aggregate size
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UNIFIED CONCRETE CODE

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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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PART 4 : DURABILITY PROVISIONS

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GOOD DETAILING PRACTICE

Detailing to improve Durability :
1. Structural Scheme

Structural Scheme :
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Example: Avoid Permanent Joints and Bearings, e.g. Integral Bridges
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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Geometry, Size & Shape effects Durability :

Drainage : Most Important for Durability
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Pier with lesser surface area / volume ratio is preferred
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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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GOOD DETAILING PRACTICE Reinforcement Detailing :
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Controlled Permeability Formwork :

1. The properties of surface skin (the cover), which is the first line of defence to protect reinforcement, remain poorer. 2. Conventional steel or timber formwork is essentially impermeable and traps the entrapped air and water that migrate towards the formwork during compaction.


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Controlled Permeability Formwork :

3. The resultant water/cement ratio in the cover zone is higher than in the bulk, and forms a weak link; having lower resistance to the ingress of air, water and CO2 etc. from the service environment. 4. Use of CPF helps to improve durability.
Concrete Formwork: With Zemdrain Vs Conventional
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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Coatings in Concrete :
1. Coatings are sometimes given : To protect it from chemical and physical attack.

Coatings in Concrete :
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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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GOOD DETAILING PRACTICE COATING ON REBAR :

COST COMPARISON ON REBAR COATING
Material Rebar without Coating Rebar with FBEC Rebar with Hot-dip Galvanized Coating Solid Stainless Steel Rebar(316) Cost Ratio 1.0 1.3 1.5 5.0
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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.
Corrossivity Map of India


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Protection Levels for pt-tendons based on aggressivity / exposure vs. structural protection layers
Source: fib bulletin 33
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THANK YOU
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Durability

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IRC:112-2011

SECTION 14 : DURABILITY PROVISIONS CONTENT OF PRESENTATION

NEW UNIFIED CONCRETE CODE Limit State Version (IRC:112-2011)

3. Severe cracking in structures in many countries resulting from alkali-silica reaction

Deterioration in Bridges from durability reasons

Factors affecting Durability

Most serious form of degradation of Concrete

Mechanical & Physical Deterioration

Chemical / Biological Deterioration

Reinforcement / Prestressing Steel Corrosion

Abrasion Erosion Plastic Shrinkage

Frost Attack Impact Thermal Effects

WHAT IS DESIGN SERVICE LIFE OF A STRUCTURE ?

DESIGN SERVICE LIFE

Mechanical & Physical Deterioration

Reinforcement / Prestressing Steel Corrosion

Abrasion Erosion Plastic Shrinkage

Frost Attack Impact Thermal Effects

RESISTANCE TO ABRASION CAN BE OBTAINED BY :

Abrasion Damage in Concrete

Freeze & Thaw Effect

Mechanical & Physical Deterioration

Reinforcement / Prestressing Steel Corrosion

Abrasion Erosion Plastic Shrinkage

Frost Attack Impact Thermal Effects

DETERIORATION MECHANISM Mechanism :

Alkali Silica Reaction

Photographs showing repair of Bridges affected by AlkaliAlkaliSilica Reactions

COMPOSITION THAT IS NOT VERY COMMON.

Effects of Chemical Deterioration : Sulphate Attack

Effects of Chemical Deterioration : Sulphate Attack

Effects of Chemical Deterioration : Sulphate Attack

Mechanical & Physical Deterioration

Reinforcement / Prestressing Steel Corrosion

Abrasion Erosion Plastic Shrinkage

Frost Attack Impact Thermal Effects

Corrosion Most serious form of deterioration in Concrete

Cracking De-lamination Spalling of cover

CORROSION PROTECTION MECHANISM & METHODS

Prevent entry at concrete surface.

If penetrates concrete surface, prevent reaching the reinforcement

Graph showing variation of Carbonation Depth with Time

If reaches reinft., control corrosion Best is to avoid reactive substance itself !

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

Not Sea Water !!

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

Clear cover to any reinft.

Example of a structure in Extreme climatic condition

SECTION 14 : DURABILITY PROVISIONS

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY

DESIGN FOR DURABILITY Adjustment for other Aggregate size

DESIGN FOR DURABILITY