1 s2.0 S0950061822024163 Main
1 s2.0 S0950061822024163 Main
1 s2.0 S0950061822024163 Main
Rebar corrosion and ASR durability assessment of fly ash concrete mixes
using high contents of fine recycled aggregates
Andrés Barragán-Ramos *, Camilo Ríos-Fresneda , Juan Lizarazo-Marriaga , Nicole Hernández-
Romero
Universidad Nacional de Colombia, Bogotá, Colombia
A R T I C L E I N F O A B S T R A C T
Keywords: This research assessed the potential alkali silica reaction (ASR) of fine recycled aggregates (FRA) derived from
Concrete durability precast concrete slabs using petrographic examination and expansion tests, the effects of incorporating FRA on
Recycled concrete aggregate some chloride related transport properties and the corrosion risk of fly ash blended concretes. Mixes incorpo
Durability of concrete
rating 20 % fly ash (FA) were produced using water-to-binder ratios of 0.45 and 0.50 and FRA replacements of 0
ASR
Steel rebar corrosion
%, 20 %, 60 % and 100 % to test concrete’s mechanical performance, chloride penetrability and rebar corrosion
risk using electrochemical techniques at different ages. FRA presented an ASR expansion 227 % higher than
natural aggregates. Using high contents (>60 %) of FRA didn’t increase corrosion risk and a comparable risk to
conventional concrete was observed when incorporating FA.
1. Introduction from the parent concrete [6]. OAM consist mainly of fully or partially
hydrated cement particles with high porosity paste adhered to natural
Construction is responsible for causing considerable environmental aggregates, which causes higher water absorption, lower density and
impact due to the extraction of natural resources and the associated lower abrasion resistance than natural aggregates [7]. The presence of
pollution resulting from their fabrication ang processing activities [1]. OAM in RCA also produces higher porosity in concrete’s microstructure
Construction also generates large amounts of waste and debris due to the that reduce their durability performance [8–10].
eventual demolition of buildings that have completed their service life. Corrosion consists of electrochemical reactions at the surface be
In the USA, 569 million tons of construction and demolition waste tween metal and an electrolyte solution. In concrete, the solid and liquid
(CDW) were generated in 2014, mainly from demolition activities, In products resulting from cement hydration form a thin layer over the
China, 30 % – 40 % of total waste consists of CDW, producing around rebar surface, known as the passive film, which protects the metal from
3000 million tons [2]. In Colombia, CDW correspond to an estimate of further corrosion. Regardless of the formation of this film, external ions
100 thousand tons per day [3]. can be transported through the concrete and in practice, corrosion is
When CDW is separated and recycled concrete aggregates (RCA) are never equals to zero but should be kept at very low levels to maintain the
used, the resulting concrete known as recycled aggregate concrete (RAC) service life of reinforced concrete [11]. The stability of metal could be
can achieve similar properties than those of conventional concrete. described in terms of its electrochemical potential (EP), which is defined
Nevertheless, little acceptance has been observed in the use of fine RCA as the ease of ionizing an atom of the metal. EP is dependent on the pH
(FRA) as the durability-related properties could not guarantee an and factors such as the oxygen and water availability. There are ranges
acceptable service life [4]. It has been reported that the replacement of of electrochemical potential and pH in which the products of corrosion
FRA increases water absorption by immersion and capillary action, and are either dissolved ions such as Fe2+, solid oxides or hydroxides. The
reduces both, carbonation and chloride migration resistances [5]; which Pourbaix diagram for iron, indicates regions of potential and PH in
are directly related to corrosion risk of the steel rebar reinforcement. The which the metals will be immune, will actively corrode or will form
negative effects of incorporating RCA in the durability of concrete could passive films. Steel bars embedded in concrete are considered to be in a
be attributed to the high amounts of old adhered mortar (OAM) derived state of passivity due to the high alkalinity of concrete [11].
Abbreviations: RCA, Recycled concrete aggregates; FRA, Fine recycled aggregates; ASR, Alkali silica reaction; FA, Fly ash; OAM, Old attached mortar.
* Corresponding author.
E-mail address: [email protected] (A. Barragán-Ramos).
https://doi.org/10.1016/j.conbuildmat.2022.128759
Received 11 April 2022; Received in revised form 9 July 2022; Accepted 8 August 2022
Available online 17 August 2022
0950-0618/© 2022 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
Chloride ions can be present in concrete due to the use of chloride- both ASR in aggregates and corrosion in concrete mixes. This paper
contaminated components, the use of de-icing salts or from environ contributes to the knowledge on the relationship between aggregate
mental exposure in coastal areas. When the chloride ions in concrete are mineral composition, alkali-silica reactivity, concrete durability per
present in the pore solution, they are called free chlorides and are formance, steel rebar corrosion and potential mitigation techniques by
responsible for initiating the corrosion process [12]. Studies have shown performing an extensive experimental research program. This paper also
that there is a linear relationship between the chloride penetrability and provides support for further research regarding RAC structural viability
the increasing replacement of RCA [13]. It has been reported that RAC from a durability perspective.
using 100 % FRA showed a migration coefficient increase of 33.8 %
compared to conventional concrete [14]. As the migration coefficient is 2. Experimental program
directly linked to concrete porosity, a reduction of chloride ion pene
tration resistance is expected when FRA are used [13,15,16]. 2.1. Materials
Alkali-Aggregate reactions are detrimental chemical reactions in
concrete that produce internal expansion and premature loss of 2.1.1. Aggregates
serviceability. In very aggressive environments with high pH (pH > Coarse natural aggregates (CNA) with a maximum size of 12.7 mm
12.5), the silica in the reactive mineral phases within the aggregates and fine natural aggregates (FNA) with a maximum size of 4.76 mm
could react deleteriously with the highly basic alkali hydroxides (K+, (Sieve No.4) were obtained from a local quarry. These natural aggre
Na+) dissolved within the micropores in the matrix of hardened concrete gates had a fluvial sedimentary origin, regular size, and partially
[17]. Studies have identified that alkali-aggregate reaction can occur in rounded edges. Fine recycled aggregates (FRA) were obtained from a
RCA when the OAM or the original natural aggregates were reactive local concrete manufacturer. FRA were derived from prefabricated
[18] and it increases for higher replacement ratios of RCA in new con structural concrete slabs designed to achieve a compressive strength of
crete [19]. The extent of the reaction depends on the supply of reactants, 35 MPa and mechanically crushed to achieve a maximum size of 4.76
if the reactant (unstable siliceous phases) had been depleted in the mm. The physical properties measured on both natural and recycled
previously affected concrete source (i.e., highly ASR-damaged RCA ag aggregates such as fineness modulus, specific gravity, absorption (ASTM
gregates), a slower “secondary” expansion is expected in new RAC C128) [30], and materials finer than 75 µm (Sieve No. 200) (ASTM
[19–21]. Due to this effect, researchers have found that RAC with C117) [31] are summarized in Table 1.
slightly damaged or highly damaged RCA may have a lower number of Regarding particle size distribution, natural aggregates showed a size
cracks than conventional concrete [21]. Different behavior has also been distribution satisfying the required gradation limits established in ASTM
observed depending on the size of the reactive recycled particles as the C33 [32]. Due to the homogeneous crushing process, the amount of FRA
reactants are consumed faster using FRA than coarse recycled aggre particles retained on sieves>1 mm was inferior to the recommended on
gates, showing an expansion reduction effect over time[20]. A delay in ASTM C33. Particle size distribution for both natural and recycled ag
expansion was also observed using highly damaged FRA and attributed gregates are shown on Fig. 1.
to the residual cement paste with a lower alkali content obstructing the
diffusion of alkalis from the new cement paste [20]. 2.1.2. Cementitious materials for concrete mixes
It has been established that the use of supplementary cementitious Commercially available blended Portland cement (C) type UG – “Uso
materials (SCM) such as fly ash (FA), silica fume, ground granulated General” (General use cement) according to Colombian regulation NTC
blast furnace slag (GGBFS), or metakaolin, can prevent ASR by reducing 121 [33] was used in the preparation of all concrete mixes. Class F fly
the alkali contribution from Portland cement, inducing pozzolanic re ash (FA) meeting the required physical properties defined in ASTM C618
actions that produce calcium silicate hydrate (C–S–H) and lowering [34] was used as a supplementary cementitious material. The physical
the pH of the pore solution [22]. Studies have found that the use of FA is properties measured for the binder (cement and fly ash) are shown in
effective to mitigate ASR on RCA; however, a higher content may be Table 2. Both types of cementitious materials are used extensively by
required compared to conventional concrete due to the additional alkali local concrete and cement manufacturers.
content provided by the OAM [18,22]. The use of fly ash (FA) can also The chemical oxide analysis performed for FA using X-ray Fluores
improve RAC’s durability to chloride penetration [23,24], as it can cence (XRF) is shown in Table 3.
enhance pozzolanic reactions that result in a denser concrete micro
structure due to the pozzolanic reaction between FA, Portland cement 2.1.3. Water reducing admixture
hydrating products and OAM [10,15]. The use of FA is also notoriously To avoid possible fresh-state performance loss and achieve the target
favorable to the increase in RAC’s electrical resistivity [25]. Different slump value, a high-range water-reducing admixture super-plasticizer
studies have concluded that the principal negative effect of incorpo (SP) made from polycarboxylates was incorporated on all concrete
rating FA to RAC is an increase in carbonation depth, as it causes a mixes. The SP composition does not include chlorides to avoid corrosive
reduction in concrete’s pH due to the pozzolanic reaction between reactions on reinforced concrete and met the requirements of American
portlandite and FA, which reduces the amount of Ca(OH)2, creating standard ASTM C494 [35] for type A water reducing-admixtures and
favorable conditions for carbonation to occur [10,15,25–29]. type F high-range water-reducing admixtures.
While the effects of incorporating FRA in concrete’s durability have
been documented, the relationship between possibly expansive aggre
gates due to ASR and corrosion in steel reinforcement has not been 2.2. Preparation of concrete mixes
assessed. The objective of this paper was to perform a microscopic
characterization of the FRA and evaluate their potential alkali-silica Mixes were cast using water/binder (W/B) ratios of 0.45 and 0.50,
reactivity. RAC mixes were also produced using different FRA contents
to identify its effects on concrete’s durability, most specifically the Table 1
properties related to chloride penetration resistance. Additionally, Physical properties of the aggregates.
electrochemical measurement techniques were carried out on steel bars Type of Apparent Absorption Fineness Materials finer
embedded into concrete specimens to measure linear polarization Aggregate Density Module than 75 µm
resistance (LPR) which is directly correlated to the corrosion rate of steel (g/cm3) (%) - (%)
reinforcement and it’s an indicative of the passivation of steel embedded CNA 2,32 4,62 – –
in concrete. This research also aimed to determine the effectivity of FNA 2,45 2,09 2,38 5,66
FRA 2,12 9,48 3,25 9,40
incorporating SCM (specifically class-F FA) as a mitigation technique for
2
A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
Table 4
Mix proportions of concrete mixes.
Mix Mix W/B* Cement Fly Ash Water Coarse Aggregates Natural Fine Aggregates Recycled Fine Aggregates Super-Plasticizer
3 3 3 3 3 3
kg/m kg/m kg/m kg/m kg/m kg/m % Binder Mass
3
A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
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A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
(a) (b)
Fig. 2. (a) Cylindrical specimens with embedded steel bar. (b) Three-point electrode system used for PR tests.
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A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
Fig. 3. PPL - XPL Microphotography of RCA with Quartz Sandstone (Qa), cement with sedimentary and metamorphic aggregates (S + M), Cement with Sedimentary
and Igneous aggregates (S + I). and Cement with Sedimentary aggregates (S).
Table 8
Potentially reactive components identified in FNA and FRA.
Reactive components content (%) Fine Recycled Aggregates Fine Natural Aggregates
Sieve Size #8 #16 #30 #50 #100 Avg #8 #16 #30 #50 #100 Avg.
Mycrocristalline Quartz 27.3 21.3 16.0 13.3 2.7 16.1 32.7 24.7 8.7 8.0 3.4 15.5
Highly Strained Quartz 48.7 37.3 38.7 16.0 7.4 29.6 26.0 20.7 24.0 18.0 16.1 21.0
Total 76.0 58.7 54.7 29.3 10.1 45.7 58.7 45.4 32.7 26.0 19.5 36.5
faster using FRA, showing an expansion reduction effect over time [20]; effective to detect potential ASR reactivity since the alkali content of
however, this reduction in the expansion rate was not observed and the OAM cannot be identified only by petrographic/microscopic
mortar mix containing 100 % FRA showed the same expansion rate even examination.
after 28 days of curing in a very aggressive environment. This may be Results from the mortar bars including fly ash, revealed an innocuous
attributed to the initial alkali content of the aggregates and the achieved expansive behavior even when employing 80 % replacement of FRA.
particle suspension of fine aggregates inside the cement matrix, which This would indicate that FA is a very effective pozzolan for reducing
may allow a higher reactant interchange. Results indicate that the ASR expansive negative reactions when using FRA. This has been observed
observed on mixes with FRA does not depend only on the mineral by other researchers who claimed that fly ash reduces the alkalinity of
composition of the aggregates, but it is also highly affected by the alkali recycled aggregates and neutralizes possible chemical reactions that
supply of the OAM. Mortar bar expansion methods may also be more result in bar expansion by reducing the pH of the fluids saturating the
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A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
mortar bars [18]. Results indicate that the use of high contents of respectively than each control mix and 6 % and 9 % higher respectively
reactive FRA may also be possible when employing supplementary than mixes 28-RA100 and 21-RA100. These results are not consistent
cementitious materials such as FA. The effectivity of FA may depend on with the reported by other researchers, who have stated that fly ash
the initial alkali content of the OAM or aggregates and the employed reduced WA and porosity due to the filling of pores, pozzolanic reaction,
content of FA. and its positive effect in density [24,28]; however, it is important to
notice that the employed FA presented a high loss on ignition value
(10.9 %) which indicates the presence of residual unburned coal and
3.3. Percent voids and water absorption by immersion organic materials.
7
A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
Fig. 7. Compressive strength (F’c) for increasing replacement ratios of fine RCA at different testing ages.
(b)
(a)
Fig. 8. Strength development curves for increasing ratios of fine RCA of (a) 0.45 W/B mixes. (b) 0.50 W/B mixes.
8
A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
to control mixes. At 90 days, the negative effect of including FA was reduced as the replacement ratio of FRA increased. Based on these re
reduced. FA could reduce the water content in early hydration and cause sults, for low replacement ratios up to 20 %, the modulus of elasticity
a delayed pozzolanic reaction that occurs between the FA and Ca(OH)2 could be calculated with the same coefficient of estimation k than nat
in RCA, which absorbs CaO and produces CSH, contributing to CCS ural aggregate concrete without expecting a significant overestimation
development [28,60]. Additionally, the high content of unburned of this parameter. For medium or high replacement ratios, a more
organic materials measured on the FA may also contribute to a loss in conservative factor could be formulated but this would result in larger
mechanical performance. The CCS development curve for mixes without structural elements in concrete buildings. Nevertheless, since only one
FA is shown in Fig. 8. At 28 days, only mix 28-CONTROL had achieved type of recycled aggregate was tested, it was not possible to establish
the CCS design value in the 0.45 W/B group, however all mixes with FRA how the calculated coefficient is related to the aggregate type or the
surpassed the CCS design value at 90 days. At 28 days, all 0.50 WB mixes source concrete.
without FA had achieved the design F’c of 21 MPa. This may indicate
that FRA could be used in low replacement ratios (up to 20 %) without
significantly affecting CCS. 3.6. Rapid chloride migration test (RCPT)
Fig. 9. Modulus of Elasticity (Ec) for increasing replacement ratios of fine RCA at 90 days.
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A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
Fig. 10. Factor for Ec estimation “k” for increasing replacement ratios of FRA at 90 days.
Fig. 11. RCPT results and ASTM C1202 limits for increasing contents of FRA.
Fig. 12. Corrosion current density of steel bars embedded in concrete specimens with increasing contents of FRA.
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A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
conductance of concrete would be more dependent on the pozzolanic negative effect should be observed in this testing period scale unless
reactions of specimens with FA rather than on its filler properties alone. corrosive reactions are triggered.
Results also indicate that for all concrete mixes, the corrosion rate of
steel bars showed values between 0.7 µm/y and 4.4 µm/y with an
3.7. Potentiodynamic polarization resistance
average value of 2.3 µm/y except for one atypically high measurement
at 120 days for mix 28-CONTROL. From these results it could be noted
The measured corrosion current density and the corrosion risk clas
that the corrosion rate of steel bars was not modified by using FRA for
sification limits are shown graphically in Fig. 12. For most concrete
the measured time, and additionally, since no clear negative tendency
mixes, a “moderate” corrosion risk was observed at all testing ages. After
could be observed and all mixes had a “moderate” risk classification, it
immersion in the 3 % NaCl solution, a clear negative effect of incorpo
could not be concluded that incorporating FRA would accelerate
rating incrementing levels of FRA could not be determined. For the 0.45
corrosion in the embedded steel bars when comparing to conventional
W/B ratio, at 28 days, steel embedded in RAC mixes showed higher
concrete, even for corrosive environments with high chloride contents.
corrosion current density, but as the age increased, the difference with
Measurements were also made to estimate the corrosion electric
the control mix was less notorious. For the 0.50 W/B ratio, steel
potential (ECORR), also called the open circuit potential, which corre
embedded in mix 21-CONTROL presented the lower corrosion current
sponds to the potential measured when no (net) current is flowing in the
density at 120 days, however a detrimental corrosion effect couldn’t be
absence of electrical connections as shown in Fig. 14. This potential is
determined from the incorporation of FRA. No reference could be found
measured against the reference calomel electrode, and the results are
in previous research works incorporating FRA; however, it has been
negative since a relative excess of electrons is present in the embedded
observed that reducing the W/B ratio will reduce corrosion current
steel bar due to the oxidation reactions in the interface. Higher electrical
density as higher resistivity in concrete mixes will increase polarization
potential values are an indicator of higher rates of corrosion due to an
resistance.
increase in electron exchange.
The effects of using FA varied depending on the age of the specimen.
Similar values of corrosion potential can be observed for steel bars
While at 28 days steel bars embedded in all mixes from the 0.45 W/B
embedded in 0.45 and 0.50 W/B ratios, obtaining absolute results be
group with FA presented a reduction in corrosion current, this behavior
tween 0.2 V and 0.425 V. No clear relationship could be established
was less evident for older specimens submerged in the NaCl solution.
between the replacement ratio of FRA and the corrosion potential of
Different studies of corrosion in steel bars embedded in FA concrete have
steel bars as the corrosion electrical potential did not increase with
noted that this mineral addition could reduce corrosion rate as the
specimen age after 3 months of curing in an aggressive environment.
modification of pH inside concrete provides passive protection to the
Since corrosion is a slow process, longer measurements should be made
steel bar and reduces chloride penetration [16,23], however, in this
after years of exposure to very aggressive environments. However, as no
research program, these positive effects were different depending on the
significant differences were noticed on this test or the other chloride-
W/B ratio, the age of the specimen and the FRA replacement ratio.
penetration related tests that would reject the use of FRA in concrete
The corrosion rate of the embedded steel bars for different concrete
from corrosion related problems, the assessed aggregate cannot be
specimen ages was also calculated from the current density. Results are
stablished as a corrosive material that enhances this reaction in rein
shown in Fig. 13. The corrosion rate was calculated in micrometers per
forcement steel bars. Furthermore, as observations from the petro
year (µm/y) and can be interpreted as the steel bar radius that would be
graphic analysis and RAS assessments indicated that the FRA are
affected each year by corrosion. Results show that corrosion rate of steel
possibly expansive due to their high alkalinity, it is expected that the
bars is not a directly time-dependent property. This is expected as it
inclusion of FRA increases the pH of concrete due to the high alkali
corresponds to a steel property rather than a concrete property and no
(a) (b)
Fig. 13. Corrosion rate results for steel bars embedded in concrete specimens for (a). 0.45 W/B mixes and (b). 0.50 W/B mixes.
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A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
(a) (b)
Fig. 14. Corrosion Potential measurements at different specimen ages for (a) 0.45 W/B mixes. (b). 0.50 W/B mixes.
supply provided by OAM. Assuming pH values for the concrete mixes with an average lifespan of 100 years should not have steel corrosion
around 12, results from the corrosion potential measurements would levels that would represent a risk in the structural integrity when
indicate that the steel bars are in a state of passivity according to the adequate cover is provided.
Pourbaix diagram for iron as shown in Fig. 15.
These values were obtained for 6 mm diameter steel bars imbedded 4. Conclusions
in 76 mm diameter concrete cylinders, representing an approximate
concrete cover of 35 mm which is a lower value than the specified for This research work aimed to assess the effects of incorporating in
aggressive environments in most building codes. Since the measure cremental levels of fine recycled concrete aggregates (FRA) in the
ments at 120 days were made after 3 months of immersing the speci durability properties of concrete with different water/binder ratio (W/
mens in an aggressive 3 % NaCl solution, RAC used in regular buildings B) related to steel rebar corrosion and the possible enhancing effects of
Fig. 15. Schematic Pourbaix Diagram for Iron including the measured potential region for the steel rebar.
12
A. Barragán-Ramos et al. Construction and Building Materials 349 (2022) 128759
using fly ash (FA). The main conclusions obtained from the mechanical the work reported in this paper.
and durability assessments are the following:
Data availability
• The assessed FRA presented higher absorption and higher voids in
aggregates than natural aggregates. This aggregate loss in perfor Data will be made available on request.
mance is the responsible for the observed reduction in concrete’s
fresh state and hardened state properties. References
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