CORROSION Testing

Malcolm Lim General Manager Proceq Technical Services

May 5, 2013

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Definition of Corrosion

Corrosion is defined as the degradation of a metal by an

electrochemical reaction with its environment

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Cracking

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Cracking

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Cracking and Falling Hazard

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Cost of Corrosion

Once corrosion starts, it is very difficult to reverse the conditions.

Annual Dollars Spent on Corrosion Related issues (construction related):
A. Approx. $100 billion dollars
B. $100 to $200 billion dollars
C. $ 200 to $300 billion dollars

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Cost of Corrosion

Once corrosion starts, it is very difficult to reverse the conditions.

Annual Dollars Spent on Corrosion Related issues (construction related):
A. Approx. $100 billion dollars
B. $100 to $200 billion dollars
C. $ 200 to $300 billion dollars

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Cost of Corrosion

Studies show that 25% to 30% of annual corrosion related cost could be
saved if optimum corrosion management practices were employed percent .
That relates to approximately $100 billion dollars in savings

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Elements of Corrosion

Metal Element

Oxygen

Water

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Factors Necessary for Corrosion to Begin

Destruction of passive layer

Presence of moisture and oxygen
Establishment of galvanic cell

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Basic Corrosion Cell

Anode
Cathode
Electrical Connection
Electrolyte

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Corrosion Cell

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Cracking and Staining

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Corrosion Cell

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Volume Change

Fe

Iron

Fe2O3

Ferric oxide

Fe3O4

Magnetite / Gthite

FeO.(OH)

Hard rust

Fe(OH)2

Ferrous hydroxide

Fe(OH)3

Ferric hydroxide

Fe2O3.xH2O

Hydrated ferric hydroxide

0

Volume Ratio

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10

Spalling

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Factors Affecting Corrosion

Cement Type
Relative Humidity
Moisture
Chlorides
Carbonation

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Carbonation

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Effects of Carbonation on Concrete

Reduces the passivity of the concrete

Reduces the pH of the concrete

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Carbonation

Carbonation is a function of:

Cement Type
Water/Cement Ratio and
Amount of Cement

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Carbonation From One Sides

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Carbonation From Both Sides on an Elevated Slab

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Carbonation From Top and Along Crack

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Factors Affecting Carbonation

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Concrete Mix

Depth,in.
0.2
0.4
0.6
0.8

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2900 psi mix 5800 psi mix

year
4 years
2
16
4
36
7
64

Max. Depth of Carbonation in Sheltered Concrete

Outdoors in UK

28-day Strength,
PSI (MPa)
2900 (20)

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Depth of Carbonation
after 30 years, mm
45

5800 (40)

17

8700 (60)

11,600 (80)

Rate of Carbonation, W/C

w/c

0.45
0.50
0.55
0.70
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cover, mm

10

15

20

25

30

19
6
3
1.2

75
25
12
5

100+
56
27
11

100+
99
49
19

100+
100+
76
30

100
100
100
43

RATE OF CARBONATION

Relative Humidity

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50
RELATIVE HUMIDITY, %

100

Testing for Carbonation

Petrographic
Use of phenolphthalein indicator
Spraying on broken away fresh surface
The carbonated surface remain clear and turn pink where concrete is still alkaline

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Rate of Carbonation Depends on

Moisture content of concrete

RH of atmosphere
Size of element
Diffusion
Time
Rain
W/C
Cement content

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Effects of Curing on Carbonation

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Proceq
Concrete Testing

Canin+
Corrosion Analyis

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Product Line Concrete Testing

SilverSchmidt

Concrete test hammer

Original Schmidt

Concrete test hammer

Digi-Schmidt

Concrete test hammer

Pundit Lab

Ultrasonic instrument

Pundit Lab +

Ultrasonic instrument

Profometer 5+

Rebar detector

Profoscope(+)

Rebar detector

Canin+

Corrosion analyzer

Resipod

Surface resistivity meter

Torrent

Permeability tester

Dyna

Pull-off tester

Hygropin

Humidity tester

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Canin+

Canin+ Corrosion Analyzing Instrument

Corrosion potential application:
accurate field potential measurements
aid in detecting corrosion in rebars.
Concrete resistivity application:
the instrument measures the
electrical resistivity of concrete.

Potential Measurement

Resistance Measurement

Memory

non-volatile memory for up to 235000

measurements

non-volatile memory for up to 5800 measurements

Range

+342 mV, -999 mV

0 to 99 kcm

Batterie

Six LR 6 batteries, 1.5 V for

up to 60 h (or 30 h with backlight)

Six LR 6 batteries, 1.5 V for

up to 40 h (or 20 h with backlight)

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Corrosion of Rebars in Concrete

Reinforced concrete will invariably be

subjected to a corrosion process that
ultimately leads to a total failure of the
structure.
In the first stage, aggressive elements such
as chloride or carbon dioxide penetrate into
the structure.
On reaching the rebars, high concentrations
of these aggressive elements attack the
passive layer of hydrated iron oxide that
protects the rebar against corrosion.
If moisture and oxygen is present, rust
begins to form which eventually leads to
structural failure.

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Corrosion Probability of a Structure

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Purpose of Testing with Canin+

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The principle of steel corrosion in concrete

Under normal conditions reinforcement steel is

protected from corrosion by a thin, passive film of
hydrated iron oxide.
This passive film is decomposed due to the
reaction of the concrete with atmospheric carbon
dioxide (CO2) (carbonation), or by the penetration
of substances aggressive to steel, in particular
chlorides from de-icing salt or salt water.
At the anode ferrous ions (Fe++) are dissolved
and electrons are set free. These electrons drift
through the steel to the cathode, where they form
hydroxide (OH-) with the generally available water
and oxygen
This principle creates a potential difference that
can be measured by the half-cell method.

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The Canin+ Measuring Principle

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The Potential Funnel

The diagram opposite shows a 3D
representation of the so-called potential
funnel, which gives an idea of the form of
the half-cell potentials which can be
measured with Canin+.
The centre of the funnel is the corrosion
hot-spot.

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Suggested Test Sequence

Planning and Preparation
Connect to the
reinforcement

Functional check
of the instrument

Check instrument
configuration

Prepare the test

surface

Is a direct measurement on the concrete surface possible?

Yes

No
Can the influence from surface coatings be
estimated and compensated?
Yes

No
Remove the surface coating

Pre-moisten the surface if required and carry out the measurement

Evaluate the data
Confirm and refine corrosion hotspot positions at openings in the concrete

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Preparation on Site

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Measurement Procedure

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4-Wheel Electrode for Fastest Results

Typically speed on site is the most
important factor.
Many customers state this fact and opt for
the four wheel electrode.
It allows them to be competitive in bidding
for contracts.
The Canin+ 4-wheel electrode system is the
fastest corrosion survey instrument
available!

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Recommended Grid Size?

Depends on resistivity of concrete.

Low electrical resistivity leads to more negative potentials that can be measured
on the surface and the potential gradients become flatter. (-> coarser grid)
High electrical resisitivity leads to more positive potentials that may be measured
on the surface and potential gradients become steeper. (-> finer grid)
BAM (Bundesamt fr Materialforschung & EFC (European Federation of
Corrosion) give a recommendation of 250mm grid.
Allows for rapid scanning and there is very little chance of missing a hotspot.

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Evaluation

Upload measured data from the Canin+

Further processing in ProVista; first view with the integrated viewer
Case by case use of the statistical evaluation
Create images
Copying images into plans, graphic design programs (e.g. CorelDraw) or CADplans

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First results in ProVista

Photo source www.concrete-concepts.eu

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Interpreting the Results

Graphic source www.concrete-concepts.eu

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Typical results

Typical orders of magnitude for the half-cell potential of steel in concrete measured
against a Cu/CuSO4- reference electrode are in the following range (RILEM TC 154EMC):
- water saturated concrete without O2: -1000 to -900 mV
- moist, chloride contaminated concrete: -600 to -400 mV
- moist, chloride free concrete: -200 to +100 mV
- moist, carbonated concrete: -400 to +100 mV
- dry, carbonated concrete: 0 to +200 mV
- dry, non-carbonated concrete: 0 to +200 mV

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Major influences on the measurement

Provided that the corrosion conditions are equal (chloride content or carbonation
of the concrete at the steel surface) the main influences upon the half-cell
potentials are:
CONCRETE COVER THICKNESS

The potential which can still be measured

at the concrete surface becomes more
positive as the concrete cover increases

ELECTRICAL RESISTIVITY

Low electrical resistivity leads to more

negative potentials and the potential
gradients become flatter.
Higher resistivity leads to steep gradients
and the grid must be made finer in order
to avoid the risk of missing an anode.

Concrete cover thickness should be measured with

Profometer/Profoscope
Electrical resistivity should be measured with the Resipod

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ProVista Tools for Evaluation

The potential ranges of active corrosion and passivity overlap.
The red cursor (leftmost) = minimum of the passive distribution.
The yellow cursor (rightmost) = maximum of the active distribution.
Active corrosion is practically certain in the region of the left hand (more negative)
straight section.

Graphic source www.concrete-concepts.eu

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Evaluation Example - Real Results

Graphic source www.concrete-concepts.eu

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Verification

Photo source www.concrete-concepts.eu

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Chipping Plan

Graphic source www.concrete-concepts.eu

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Corrosion Rate Measurement Two Step Process

STEP 1 CORROSION MAP using CANIN+

It is necessary to carry out a half cell potential survey of the site to
determine the locations at which corrosion rate measurements should be
made.
THE FASTEST WAY TO DO THIS IS TO USE THE CANIN+ WITH THE
1-WHEEL ELECTRODE OR 4-WHEEL ELECTRODE (FOR LARGER
SURFACES)!
This allows the customer to identify the locations at which a corrosion rate
measurement can be made.
STEP 2 CORROSION RATE
Carry out the corrosion rate measurement. However, it must be noted that
accurate measurements and the corresponding analysis thereof depend
very much on 3 key factors:
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Factors Affecting Corrosion Rate Measurement 1

Factor 1 - The measurement only shows the instantaneous corrosion rate

The corrosion rate measurement only gives the instantaneous value. It gives no
indication of how much corrosion has already taken place or how the corrosion
rate will vary in future.

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Factors Affecting Corrosion Rate Measurement - 2

Factor 2 - The rebar size must be known.

The corrosion rate is based on measuring the corrosion current [A]. In
order to convert this to a corrosion rate [m/Year] it is necessary to know
the size of the corroding anode.
The Profoscope or Profometer can be used to determine the rebar size.
If more accuracy is required then it is necessary to make an opening and
inspect the reinforcement. Again the cost of this operation can be
significantly reduced by means of a preliminary assessment using the
half-cell potential measurement.

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Factors Affecting Corrosion Rate Measurement - 3

Factor 3 - Corrosion rate significantly varies with temperature and humidity

The actual corrosion rate is influenced significantly by environmental conditions
such as temperature and humidity. Corrosion rate increases under warm weather
conditions. Corrosion rate also increases under wet and humid conditions as this
lowers the resisitivity of the concrete.
In order to make an accurate determination of corrosion rate it is necessary to
make repeated measurements at the same location under known conditions.

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Application

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Application

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Proceq
Concrete Testing

Resipod

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Resipod Development - 1
In 2002 The Florida Department of Transportation started a three
phase research program to characterize the chloride penetration
resistance of concretes using Florida materials.
The objective was primarily to determine an empirical correlation
between the standard methods for determining chloride permeability
AASHTO T277 RCP (Rapid Chloride Permeability), AASHTO T259
(Bulk Diffusion Test) and the resistivity of water saturated concrete.
If this were successful, SR (Surface Resistivity) could be introduced as
an AASHTO standard for use as a quality control electrical indicator of
permeability instead of the more labor intensive RCP.
Testing was carried out with the RM MKII of CNS Farnell which was
evaluated as the most accurate instrument available at the time.
AASHTO = American Association of State Highway and Transportation Officials

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Resipod Development - 2

Cut and Epoxy

Desiccate

RCP Cell

Performing Test

26th Curing Day

27th Curing Day

28th Day

28th Day

RCP test is extremely labour intensive and time consuming

In comparison, the SR test takes about 10 minutes!

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Resipod Development - 3
The correlation between RCP and Surface Resistivity
measurements was proven to be very good
Chini, A. et al

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Resipod Development - 4
As the RM MKII used for the tests was becoming obsolete, Proceq agreed to
develop a new instrument with the features required by FDOT.

Resipod was used in round robin testing for the new standard
alongside the RM MKII and proved to be equally accurate, while
bringing many additional benefits.

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Resipod Development - 5
A new AASHTO provisional standard has been created based
on the results of the FDOT testing.

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Louisiana DOT

$101000 savings in
the first year
$1.5 million savings
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Resipod Improvements

Features

Resipod

RM MKII

Canin Wenner Probe

Price

2800 CHF

4140 CHF

4850 CHF

0 to ca. 1 Mcm

Up to 2 Mcm

0 to 99 kcm

Range (resistivity)

High contact resistance warning

+/- 0.2kcm or +/- 1%

(whichever is greater) with
nominal current 200A
Yes

Variable probe spacing possible

Resolution

1 kcm

Yes

PC Interface

USB

RS232

PC Software included

Yes

Onboard memory

Yes

Yes

Integrated instrument

Yes

Yes (Floats)

Waterproofing

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+/- 2%

Resipod Measuring Principle

A current is applied to
the two outer probes
and the potential
difference is measured
between the two inner
probes. The current is
carried by ions in the
pore liquid. The
calculated resistivity
depends on the
spacing of the probes.
Resistivity = 2aV/l
[kcm]

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Resipod Models

- The 50 mm probe
spacing model
conforms to the
accepted industry
standard.
- The 38 mm (1.5)
probe spacing model
conforms to the
specification of the
AASHTO surface
resistivity test method.

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Physical Layout
Display

ON/OFF
Hold
Save

USB
Save

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ON/OFF
Hold

Measuring Resistivity with Resipod

The concrete surface must not be
coated with any electrically insulating
coating and it should be clean. The
rebar grid beneath the surface should
be marked out with the help of a rebar
locator. (E.g. Profoscope)
Dip the contacts in water several times
before making a measurement.
Press the Resipod firmly down until the
outer two rubber caps rest on the
surface to be tested

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Indication of a poor connection

Open Line indication.

Bad connection of the two outer
probes to the concrete surface. No
measurement possible.

Inner two probes are not making

contact.(check for holes or dry spots
on the specimen)
Overflow. The measured resisitivity is
out of range. Typically a resistivity of
>1000 kcm.

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Measuring on site Influence of rebars

The presence of rebars disturbs electrical resisitivity
measurements as they conduct current much better than the
surrounding concrete. This is particularly the case when the
cover depth is less than 30mm.
Use a rebar locator (Profoscope, Profometer) to
determine the rebar location and cover depth.
As far as possible, reinforcement bars should not be directly
beneath the probe and should not run parallel to the probe.
The optimum orientation is to measure diagonally to the
rebars as shown. This is possible if the probe span is less
than the rebar grid spacing.
If the rebar spacing is so close that it cannot be avoided, the
influence of the steel can be minimized by measuring
perpendicular to the rebars as shown.

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Measuring on site Other Influences

Aggregate Size
Minimum spacing of probes depends on the maximum size of aggregates. The larger the aggregate the
greater the required minimum spacing. The greater the spacing , the greater is the depth of the concrete
that contributes to the measurements.
Temperature
Resistivity decreases as the temperature increases. Reference values for resistivity measurements are
typically quoted for 20C. Empirical studies have shown that a one degree increase in temperature can
reduce the resistivity by 3% for saturated concrete and 5% for dry concrete.
Moisture content
A higher moisture content lowers the resistivity. This can be due to saturation or due to a change in the
water/cement ratio
Carbonation
Carbonated concrete has a higher resistivity than concrete without carbonation, however provided the
depth of the carbonated layer is significantly smaller than the probe spacing, the effect of this layer is
small. Consequently if the carbonated layer is thick, it may be necessary to increase the probe spacing to
obtain good results.

77
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Application 1 Likelihood of corrosion

Empirical tests have arrived at the following threshold values for the measured
resistivity which can be used to determine the likelihood of corrosion.
When 100 kcm
When = 50 to 100 kcm

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corrosion is unlikely
risk of corrosion is low

When = 10 to 50 kcm

risk of corrosion is moderate

When 10 kcm

risk of corrosion is high

Application 3 Installation of Cathodic Protection Systems

Acceptable Electrical Resistivities of Concrete

Repairs for Cathodic Protection Systems
The general recommendation in BS EN 12696:2000 is that any repair concrete should have a
resistivity in the range 50% to 200% of the parent concrete (section 5.10.4) and that old repairs
exceeding these values should be replaced (section 5.10.3).
The product literature for galvanic anodes recommends either a limit of 15 kohm.cm or the BS EN
12696:2000 limit of 50% to 200% of the parent concrete.
Methods of measuring the resistivity of concrete both in the laboratory on prism samples and on site
structures are given in RILEM TC-154 Technical Recommendation. It should be noted that the
document states that in the field, a coefficient of variation of 30% in resistivity measurements is normal.

Information taken from Corrossion Prevention Association

Technical Note 19 by John P. Broomfield

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Application 4 Curing Efficiency

On site assessment of curing efficiency

Resistivity measurements may be used on site to determine premature drying of concrete.
This is a particularly important application in hot countries where premature drying out can
lead to structural weakening due to non-completion of the hydration reaction. The method
depends on comparing site measurements with measurements made on a saturated
reference cylinder.

Source from : Electrical Resistivity as a tool to on site

assestment for Curing Efficienty , L.Fernandez Luco,
C.Andrade, MA Climent

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Resipod - Waterproofing
Florida DOT make a lot of measurements
on bridges directly from boats with a view
to collecting data for the implementation
of cathodic protection systems.
They requested that the new Resipod
should float.
While we dont recommend holding it
under a tap as seen here during prototype
testing, waterproofing of the Resipod was
a major design consideration.

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ResipodLink Data Review

Data uploaded from the

Resipod displayed on
the PC, allowing ease
of data analysis and
export to third party
programs.

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Extension Cable Set - 1

The extension cable set
allows the Resipod to be
used with a variable spaced
probe
and
with
user
accessories as desired.

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Extension Cable Set - 2

A separately supplied holder
allows the probe extensions
to be mounted at a spacing
defined by the user.

The
appropriate
contact
spacing can be set using the
Resipod Link software and
downloaded
onto
the
Resipod.

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Extension Cable Set - 3

The user may also connect
his own accessories in place
of the standard probe
connectors.
An example test set up is
shown
here
for
direct
resistivity (or bulk resistivity)
measurement.

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QUESTIONS

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QUESTIONS

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Rate of Carbonation, Strength

Depth, in.
0.2

2900

5800
4

0.4

16

0.6

36

0.8

64

Depth of Carbonation - Smolczyk

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Age
Strength, psi