Evaluation of Corrosion Damage in Sulfate-Attacked Concrete by CT, Ultrasonic Pulse Velocity Testing and AHP Methods.

Coarse aggregate in concrete is basically free from sulfate corrosion. If the influence of the coarse aggregate in the concrete is not eliminated, the change amount of the concrete ultrasonic pulse velocity value is directly used to evaluate the damage degree of sulfate corrosion in the concrete, and the results are often inaccurate. This paper presents an evaluation method of corrosion damage for the sulfate-attacked concrete by CT, ultrasonic velocity testing and AHP methods. CT was used to extract the coarse aggregate information in the specimen, and the proportion of coarse aggregate on the ultrasonic test line was calculated based on CT image analysis. Then, the correction value of ultrasonic pulse velocity (UPV) of the concrete structure was calculated, and the sulfate corrosion degree of concrete structure was evaluated using the analytic hierarchy process (AHP). The results show that the evaluation method proposed in this paper could more accurately evaluate the corrosion damage in the sulfate-attacked concrete structures, and the evaluation results were more in line with reality.

Performance Testing of Hydraulic Cements: Measuring Sulfate Resistance.

The sulfate resistance of cements used in the construction industry is traditionally assessed by measuring the expansion of a prism of 280 mm (11inch) length and 25 mm (1 inch) square cross section immersed in a sodium sulfate solution for at least one year. The duration of the experiment limits this test from being used as a performance-based determination of innovative mixtures of cementitious materials. In response to the need for a more rapid test protocol, the National Institute of Standards and Technology (NIST) has developed a new test method that measures the expansion of smaller bars (10 mm × 10 mm × 60 mm) made with neat cement paste. With these bars, similar expansion is achieved in less than 3 months, reducing the test duration by a factor of at least 4. This accelerated test method provides more rapid results consistent with the traditional test procedure, allowing for a shorter decision time and the screening of more materials.

Investigation of damaged interior walls using synchrotron-based XPS and XANES.

Evidence of internal sulfate attack in field exposure was demonstrated by the damaged interior wall of a three-year-old house situated in Nakhon Ratchasima Province, Thailand. Partial distension of the mortar was clearly observed together with an expansion of a black substance. Removal of the black substance revealed a dense black layer. This layer was only found in the vicinity of the damaged area, suggesting that this black material is possibly involved in the wall cracking. By employing synchrotron-based X-ray photoelectron spectroscopy (XPS) and X-ray absorption near-edge structure (XANES) techniques, the unknown sample was chemically identified. The S 2p and O 1s XPS results mutually indicated the existence of sulfate species in the materials collected from the damaged area. The XANES results indicated the presence of ferrous (II) sulfate, confirming sulfate-induced expansion and cracking. The sulfate attack in the present case appeared to physically affect the structure whereas the chemical integrity at the molecular level of the calcium silicate hydrate phase was retained since there was a lack of spectroscopic evidence for calcium sulfate. It was speculated that internal sulfate probably originated from the contaminated aggregates used during the construction. The current findings would be beneficial for understanding the sulfate-attack mechanism as well as for future prevention against sulfate attack during construction.

Microstructural Origins of Cement Paste Degradation by External Sulfate Attack.

A microstructure model has been applied to simulate near-surface degradation of portland cement paste in contact with a sodium sulfate solution. This new model uses thermodynamic equilibrium calculations to guide both compositional and microstructure changes. It predicts localized deformation and the onset of damage by coupling the confined growth of new solids with linear thermoelastic finite element calculations of stress and strain fields. Constrained ettringite growth happens primarily at the expense of calcium monosulfoaluminate, carboaluminate and aluminum-rich hydrotalcite, if any, respectively. Expansion and damage can be mitigated chemically by increasing carbonate and magnesium concentrations or microstructurally by inducing a finer dispersion of monosulfate.

Effect of Exposure Conditions on Mortar Subjected to an External Sulfate Attack.

This study aims to investigate the influence of exposure conditions on the behavior of mortar subjected to an external sulfate attack (ESA). Three different exposure conditions (full immersion, semi-immersion, and drying/wetting cycles) were tested on mortar prisms made with Portland cement and two w/c ratios (0.45 and 0.6). To monitor degradation, it was necessary to evaluate variations in length (expansion), mass changes, compressive and tensile strengths, changes in the total porosity measured using water accessible porosity tests, and changes in the macroscopic behavior of the samples. Mercury intrusion porosimetry (MIP) was used to determine the size distribution of the pores. It was demonstrated that mixing mortar with the lower w/c ratio of 0.45 results in improved performance against an ESA. This study also demonstrates that the type of exposure to an ESA has no significant effect on the kinetics of sulfate penetration during the exposure period. However, the sample's surface becomes more cracked when subjected to repeated drying and wetting cycles. For all the considered exposure conditions, expansion occurred in three stages. In stage 1, the reaction product (ettringite) precipitated in large voids, without causing significant expansion (the expansion remained low and stable). During the second stage, the reaction products generated growing internal stress. The final stage of expansion resulted in microcracks, strength losses, and the formation of macropores, which ultimately lead to material failure. The MIP results indicate that major changes in the porosity and pore volume distribution occur at the surface layer in regard to the gel and capillary pore ranges.

Modeling of Concrete Deterioration under External Sulfate Attack and Drying-Wetting Cycles: A Review.

This paper comprehensively summarizes moisture transport, ion transport, and mechanical damage models applied to concrete under sulfate attack and drying-wetting cycles. It highlights the essential aspects and principles of each model, emphasizing their significance in understanding the movement of moisture and ions, as well as the resulting mechanical damage within the concrete during these degradation processes. The paper critically analyzes the assumptions made in each model, shedding light on their limitations and implications for prediction accuracy. Two primary challenges faced by current models under sulfate attack and drying-wetting cycles are identified: the limited consideration of the coupled effects of chemical and physical attacks from sulfate, and the unclear mechanism of the sulfate attacks. Future research directions are proposed, focusing on exploring the transport mechanism of sulfate ions under various driving forces and further clarifying the crystallization process and expansion damage mechanism in concrete pores. Addressing these research directions will advance our understanding of sulfate attack under drying-wetting cycles, leading to improved models and mitigation strategies for enhancing the durability and performance of concrete structures.

Durability Performance of Basalt Fiber-Reinforced Concrete Subjected to Sulfate-Magnesium Combined Attack.

In salt lake areas, cast-in situ concrete structures are subjected to long-term corrosion by sulfate and magnesium ions. The properties of concrete can be improved by adding materials like basalt fiber (BF). To investigate the degradation process and mechanism of cast-in situ concrete with premixed BF under the dual corrosion of sulfate and magnesium salts, concrete with a content of BF ranging from 0 to 0.5% was prepared. Specimens were subjected to different internal and external corrosion conditions and immersed for 180 days. Dimension, mass, and appearance changes at different immersion times were recorded. The compressive and flexural strength of the specimens were tested and continually observed throughout the immersion time. Mineral and microstructural changes at different immersion times were determined by the XRD, TG, and SEM analysis methods. Results indicated that external sulfate-internal magnesium combined attack had a significant negative effect on the early strength. The compressive and flexural strength of the corroded specimens decreased by 17.2% and 14.1%, respectively, compared to the control group at 28 days. The premixed magnesium ions caused the decomposition of the C-S-H gel, resulting in severe spalling and lower mechanical properties after immersing for a long time. As the BF can inhibit crack development, the properties of the concrete premixed with BF were improved. Specimens exhibited superior performance at a BF content of 0.5%, resulting in a 16.2% increase in flexural strength. This paper serves as a valuable reference for the application of basalt fiber-reinforced concrete under the challenging conditions of sulfate-magnesium combined attack.

Effect of Sulfate Attack on the Expansion Behavior of Cement-Treated Aggregates.

The expansion induced by sulfate attack on cement-treated aggregates (SACA) is a well-known problem that can be solved. It causes obvious heaves in road bases and railway subgrades. In this paper, the effects of the sodium sulfate content, cement content, degree of compaction, sulfate types, attack types, aluminum ion supply, concentration of curing sulfate solution, and temperature on the expansion behavior induced by SACA were investigated over 60 days in the laboratory. Based on the Sobol sensitivity analysis method, the influence of the sensitivity of each factor on the expansion was quantitatively analyzed, and the dominant factor of expansion was proposed. Results show that sulfate content is the domain factor of expansion that is induced by SACA, and it presents a logarithmic function relationship with strain. The 0.5% sodium sulfate content is the minimum sulfate content which causes the expansion that is induced by SACA. When the sulfate content is less than 1%, the expansion induced by SACA is minor. When the sulfate content is between 1% and 3%, the expansion behavior is expressed in four stages as follows: rapid strain increase, followed by a short stagnation period, then a significant strain increase and, finally, constant strain. When the sulfate content is greater than 5%, there are two stages comprising the expansion behavior as follows: the rapid strain increases and constant strain occurs. Greater sulfate content, greater degree of compaction, and lower temperature have positive effects on the expansion induced by SACA. The cement content does not have a consistent effect on expansion behavior. Compared with a sodium sulfate attack, both the reaction rate and expansion of cement-treated aggregates that are attacked by gypsum are smaller, and the attack period is also longer. When the sulfate content is greater than 1%, the addition of kaolin promotes the progression of the expansion induced by SACA. A small amount of water is sufficient for the demand for the sulfate attack. When the sulfate content is at a certain level, the expansion induced by SACA that is under external attack is much smaller than the expansion that is under internal attack. This study is expected to serve as a reference for future research on the mechanics of SACA, and it attempts to provide theoretical support for amending expansions that are induced by SACA.

The Improving Role of Basalt Fiber on the Sulfate-Chloride Multiple Induced Degradation of Cast-In-Situ Concrete.

In salt lake areas, the cast-in-situ concrete structure has been corroded by the combination of sulfate and chloride for a long time. The incorporation of basalt fiber materials into concrete helps to improve the durability of concrete. In this paper, experiments were conducted to study the corrosion deterioration mechanisms of basalt fiber-reinforced cast-in-situ concrete under sulfate, chloride, and combined attack. The appearance, size, mass, flexural, and compressive strength of specimens were investigated during the immersion period to determine the changes in the physical and mechanical properties of specimens. Moreover, the microstructure and mineral changes of specimens during the immersion period were observed by Scanning Electron Microscope (SEM), Energy Dispersive Spectrometer (EDS), X-ray diffraction (XRD), and Thermogravimetric (TG)/ Derivative Thermogravimetric (DTG) analyses. Results show that premixed chloride has a significant detrimental influence on the strength development of cast-in-situ concrete, with concrete powder spalling occurring on the surface of the specimen. Severe corrosion degradation of specimens occurs under the external sulfate and internal chloride combined attack, resulting in lower flexural and compressive strength. The compressive strength and flexural strength of the corroded specimens decreased by 15.4% and 24.8%, respectively, compared with the control group at 28 days. Moreover, premixed basalt fiber has a beneficial influence on cast-in-situ concrete. When the basalt fiber content is 0.5%, the flexural strength of the specimen is increased by 16.2%. The filling and bridging effect of basalt fiber alleviates the negative effects caused by corrosion. In addition, increasing fiber content is beneficial for enhancing its effectiveness when the fiber content is less than 0.5%. This paper provides a valuable reference for the application of basalt fiber-reinforced cast-in-situ concrete under the condition of sulfate-chloride compound corrosion.

Rapid Assessment of Sulfate Resistance in Mortar and Concrete.

Extensive research has been conducted on the sulfate attack of concrete structures; however, the need to adopt the use of more sustainable materials is driving a need for a quicker test method to assess sulfate resistance. This work presents accelerated methods that can reduce the time required for assessing the sulfate resistance of mixtures by 70%. Class F fly ash has historically been used in concrete mixtures to improve sulfate resistance. However, environmental considerations and the evolving energy industry have decreased its availability, requiring the identification of economically viable and environmentally friendly alternatives to fly ash. Another challenge in addressing sulfate attack durability issues in concrete is that the standard sulfate attack test (ASTM C1012) is time-consuming and designed for only standard mortars (not concrete mixtures). To expedite the testing process, accelerated testing methods for both mortar and concrete mixtures were adopted from previous work to further the development of the accelerated tests and to assess the feasibility of testing the sulfate resistance of mortar and concrete mixtures rapidly. This study also established criteria for interpreting sulfate resistance for each of the test methods used in this work. A total of 14 mortar mixtures and four concrete mixtures using two types of Portland cement (Type I and Type I/II) and various supplementary cementitious materials (SCMs) were evaluated in this study. The accelerated testing methods significantly reduced the evaluation time from 12 months to 21 days for mortar mixtures and from 6 months to 56 days for concrete mixtures. The proposed interpretation method for mortar accelerated test results showed acceptable consistency with the ACI 318-19 interpretations for ASTM C1012 results. The interpretation methods proposed for the two concrete sulfate attack tests demonstrated excellent consistency with the ASTM C1012 results from mortar mixtures with the same cementitious materials combinations. Metakaolin was shown to improve sulfate resistance for both mortar and concrete mixtures, while silica fume and natural pozzolan had a limited impact. Using 15% metakaolin in mortar or concrete mixtures with Type I/II cement provided the best sulfate resistance.

Mechanism and Performance Control Methods of Sulfate Attack on Concrete: A Review.

For concrete structures in marine or groundwater environments, sulfate attack is a major factor contributing to the degradation of concrete performance. This paper analyzes the existing literature on the chemical reactions and physical crystallization effects of sulfate attack on cement-based materials, summarizing the degradation mechanisms of corroded concrete. Experiments have been conducted to study the performance evolution of concrete under sulfate attack, considering both external environmental factors and internal factors of the cement-based materials. External environmental factors, such as the temperature, humidity, concentration, and type of sulfate solutions, wet-dry cycles, freeze-thaw cycles, chloride coupling effects, and stray currents significantly impact sulfate attack on concrete. Internal factors, including internal sources of corrosion, the chemical composition of the cement, water-cement ratio, and the content of C-S-H gel and Ca(OH)2, influence the density and sulfate resistance of the cement-based materials. Additionally, five typical methods for enhancing the sulfate resistance of concrete are summarized. Finally, the paper identifies current challenges in the study of corroded concrete and proposes directions for future research.

Durability analysis of metakaolin recycled concrete under sulphate dry and wet cycle.

This study aims to enhance the durability, cost-effectiveness, and sustainability of recycled fine aggregate concrete (RFAC) subjected to the combined effects of wet-dry cycles and sulfate erosion. Dry-wet cycle tests were conducted in RFAC with different admixtures of biotite metakaolin (MK) and 15% fly ash (FA) mix (M) under 5% sulfate erosion environment. The effect of 0%, 30%, 60% and 90% recycled fine aggregate (RFA) replacement of natural fine aggregate on mass loss, cubic compressive strength, relative dynamic modulus test of RFAC, damage modeling and prediction of damage life of concrete were investigated. The results showed that the concrete cubic compressive strength and relative dynamic modulus were optimal for recycled concrete at 15% MK biotite dosing and 60% RFA substitution, and its maximum service life was accurately predicted to be about 578 cycles under 5% sulfate dry-wet cycling using Weibull function model. This study is pioneering in addressing the durability of RFAC under sulfate attack combined with wet-dry cycling, employing a novel approach of incorporating MK and FA into RFAC. The findings highlight the practical application potential for using MK and FA in RFAC to produce durable and sustainable construction materials, particularly in sulfate-exposed environments. This research addresses a critical challenge in the construction industry, providing valuable insights for developing more durable and eco-friendly construction materials and contributing to long-term sustainability goals.

Study on the Resistance of Concrete to High-Concentration Sulfate Attack: A Case Study in Jinyan Bridge.

Concrete structures face significant challenges in sulfate-rich environments, where sulfate attack can affect their durability and structural integrity. This study explores innovative approaches to enhancing concrete performance by integrating hydrophobic and densification technologies. It emphasizes the critical role of anti-sulfate erosion inhibitors in mitigating sulfate-induced damage, reducing water absorption, and inhibiting corrosive reactions. This research addresses prevalent issues in Chinese engineering projects where high sulfate concentrations are common, necessitating robust solutions for sulfate resistance. Through rigorous testing, including wet-dry cycling tests with 5% and 10% Na2SO4 solutions following the GB/T 50082-2009 standard, concrete formulations achieved exceptional long-term sulfate resistance, meeting or exceeding KS200-grade requirements. These findings provide valuable insights into optimizing concrete durability in sulfate-rich environments, offering practical strategies to enhance infrastructure resilience and reduce maintenance costs.

Durability Properties of Macro-Polypropylene Fiber Reinforced Self-Compacting Concrete.

Concrete is one of the most commonly used construction materials; however, its durability plays a pivotal role in areas where the concrete is exposed to severe environmental conditions, which initiate cracks inside and disintegrate it. Randomly distributed short fibers arrest the initiation and propagation of micro-cracks in the concrete and maintain its integrity. Traditional polypropylene fibers are thin and encounter the problem of balling effects during concrete mixing, leading to uneven fiber distribution. Thus, a new polypropylene fiber is developed by gluing thin ones together, forming macro-polypropylene fibers. Thus, different amounts of fibers, 0-1.5% v/f with an increment of 0.5% v/f, are used in different grades of concrete to study their impact on durability properties, including resistance to freezing and thawing cycles, sulfate, and acid attacks. A total of 432 cube samples were tested at 28, 56, and 92 days. The results reveal that the maximum durability, in terms of compressive strength loss, is noted with a fiber content of 1% with improved resistance of 72%, 54%, and 24% against freeze-thaw cycles, sulfate attack, and hydrochloric acid attack, respectively, at 92 days. Thus, the resulting fiber-reinforced concrete may be effective in areas where these extreme exposure conditions are expected.

Circular design, material properties, service life and cradle-to-cradle carbon footprint of lime-based building materials.

The massive extraction of virgin raw materials has substantially intensified the focus on circular economy of building materials. As a Cradle-to-Cradle service life and circular approach for lime-based construction materials (LBCM) is lacking, the present study evaluates the environmental impact and feasibility of creating a fully recycled second-life render (SL) by designing a closed-loop upcycling process for first-life renders (FL). To achieve this, a second-life binder was thermally activated (900, 1000, 1100, 1200 °C), while its microstructure, compressive strength, and thermal conductivity were investigated. SL had up to 33 % open porosity (FL 29 %), its compressive strength ranged from 2.5 to 3.4 MPa (FL 4.4 MPa) and the thermal conductivity from 1.002 to 1.107 W/mK (FL 1.231 W/mK). Resistance of SL and FL against sulfate attack was found to be equivalent, measured based on the recent RILEM TC 271-ASC recommendation. The environmental impact indicators integrating material properties and durability confirm that the second life-render can reduce CO2 emissions up to 55 %. The present research provides insights into unlocking essential sustainability gains through circular practices in the life-cycle of LBCM.

Performance of a New Grouting Material under the Coupling Effects of Freeze-Thaw and Sulfate Erosion.

In order to study the performance of a new cement-based grouting material under the coupling of freeze-thaw cycle and sulfate erosion, tests related to the performance of the new grouting material were designed and carried out to analyze the damage mechanism of the material under the coupling of freezing and thawing and Na2SO4 solution by testing the mass change, relative dynamic elastic modulus, compressive strength loss and mineralogical and microstructural properties of the new grouting material. The test results show that with the increase in the number of freeze-thaw cycles, the mass loss and compressive strength loss of the specimens in 15% Na2SO4 solution gradually increased, and the relative dynamic elastic modulus showed a decreasing trend. When the freeze-thaw cycle number was 30, the mass loss rate, compressive strength loss rate and relative dynamic elastic modulus of the specimens in Na2SO4 solution were 4.17%, 24.59% and 84.3%, respectively, which showed better erosion and frost durability. Mineralogical and microstructural analysis showed that SO42- in solution led to the decomposition of the C-S-H gel and the formation of CaSO4•2H2O inside the specimen, and the internal deterioration was exacerbated by the widening of the crack width being aggravated, suggesting that the rate of material deterioration under the coupling of the two factors increased.

Experimental-Computational Investigation of the Elastic Modulus of Mortar under Sulfate Attack.

External sulfate attack is an important factor causing a decrease in the mechanical properties of cement-based materials. In this paper, a computational prediction model of elastic modulus, considering the characteristics of sulfate corrosion from outside to inside and the influence of the interface transition zone (ITZ), was established to predict the elastic modulus of mortar under the external sulfate attack. Firstly, the backscattered electron (BSE) images of mortar and the algorithm of image threshold segmenting were used to determine a reasonable thickness of corroded ITZ. Secondly, the nanoindentation test was adopted to acquire the microscopic elastic parameters of phases (sand, cement, and ITZ) in corroded mortar. Moreover, the mortar mix proportion and Lu and Torquato's model were adopted to calculate the volume fractions of phases. Finally, a computational prediction model of elastic modulus of mortar under sulfate attack was proposed with homogenization methods. The results indicate that the thickness of corroded ITZ is 20 mm, and the error values of elastic modulus between the theoretical prediction results and the experimental results are within 8%, indicating that the macroscopic elastic modulus of corroded mortar can be precisely predicted by the computational prediction model of elastic modulus.

A Micromechanical-Based Semi-Empirical Model for Predicting the Compressive Strength Degradation of Concrete under External Sulfate Attack.

As one of the most harmful ions in the environment, sulfate could cause the deformation and material deterioration of concrete structures. Models that accurately describe the whole chemo-transport-mechanical process of an external sulfate attack (ESA) require substantial computational work and contain complex parameters. This paper proposes a semi-empirical model based on micromechanical theory for predicting the compressive strength degradation of concrete under an ESA with basic properties of the undamaged material and limited computational effort. A simplified exponential function is developed for the total amount of the invading sulfate, and a second-order equation governs the chemical reaction. A micromechanical model is implemented to solve the mechanical response caused by an ESA. The model is able to describe the compressive stress-strain behavior of concrete subject to uniaxial loading in good agreement with the experimental results. For the case of a sulfate-attacked material, the relationship between compressive strength and expansion is calculated and validated by the test results. Finally, the deterioration process of compressive strength is predicted with the test results of deformation.

The Influence of External Sulfate Attack on the Durability of Reinforced Mortars in the Presence of Calcined River Sediments.

In France, the annual volume of dredged sediments is significantly increasing, which has become a real environmental problem. Nevertheless, these sediments can be used beneficially as supplementary cementing material. On the other hand, external sulfate attack is one of the most aggressive causes of deterioration that affects the durability of concrete structures. This study focused on the valorization of river-dredged sediments from Noyelles-Sous-Lens (Hauts-de-France) as a mineral addition in substitution of Portland cement, and it studied their impacts on the mechanical behavior and durability of reinforced mortars. X-ray diffraction (XRD) analysis indicated the presence of clay minerals in the raw sediment. In order to activate this clay fraction, flash calcination was applied at a temperature of 750 °C. In addition, four mixed mortars were formulated by mixing a Portland cement (CEM I 52.5 N) and the calcined sediments as a partial substitute for cement with proportions of 0%, 15%, 20%, and 30%, then stored in water tanks at room temperature (20 ± 2 °C) for 90 days in order to immerse them in a tank containing a 5% MgSO4 solution and to track the evolution of their corrosion potential as well as their mass variations every 20 days for a period of 360 days. The following additional tests were carried out on these mortars: tests of resistance to compression and flexion and to porosity by mercury intrusion. The results obtained from the majority of these tests showed that the mortar containing 15% calcined sediments is as effective and durable as the reference mortar itself. The main conclusion we can draw from these results is that the presence of these calcined sediments improves the overall behavior of the mortar.

Durability of concrete incorporating organic light-emitting diode (OLED) display waste as cement binder replacement.

The use of supplementary cementitious materials is customary in contemporary concretes. Different industrial by-products and waste materials have been investigated earlier for such applications. In this paper, the use of organic light-emitting diode glass (OLED) display waste as a partial replacement of cement binder in concretes has been explored. Concretes with 10%, 20%, and 30% substitution (by weight) of ordinary Portland cement (OPC) by OLED powder were developed, and the resulting mechanical properties and durability characteristics were evaluated. The results showed that OLED addition leads to strength improvement of up to 8% after 28-day age. Also, the resistance to chloride-ion penetration and sulfate attack improved considerably. The chloride binding capacity for the developed concretes was also investigated. It was demonstrated that the OLED powder incorporation is beneficial in improving the corrosion resistance of the modified concrete. The enhanced mechanical and durability properties of modified concrete point toward the excellent performance of OLED-incorporated concrete for improved service life. Incorporating OLED display waste in concrete as a partial cement replacement can also reduce environmental burden and concrete cost.