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factors which can cause concrete to breakdown as water can freeze and thaw on its
surface.
Following sections will discuss in detail, regarding the types and reasons behind concrete
cancer.
1. AGGREGATE EXPANSION
Various types of concrete undergo chemical reactions in concrete, leading to
damaging expansive phenomena. The most common are those containing reactive
silica, that can react (in the presence of water) with the alkalis in concrete (K2O and
Na2O coming principally from cement). Among the more reactive mineral
components of some aggregates are opal, chalcedony, flint and strained quartz.
Following the alkali-silica reactions (ASR), expansive gel forms that create extensive
cracks and damage on structural members. On the surface of concrete pavements, the
ASR can cause pop-outs, i.e. the expulsion of small cones (upto 3cm in diameter) in
correspondence of aggregate particles.
When some aggregates containing dolomites are used, a dedolomitization reaction
occurs when the magnesium carbonate compound reacts with hydroxyl ions and
yields magnesium hydroxide and a carbonate ion. The resulting expansion may cause
the destruction of the material. Far less common are pop-outs caused by the presence
of pyrite, an iron sulphide that generates expansion by forming iron oxide and
ettringite. Other reactions and recrystallization e.g. hydration of clay minerals in some
aggregates may lead to destructive expansion as well.
2. CORROSION OF REINFORCEMENT BARS
Corrosion of the reinforcement steel however, is by far the most common cause of
spalling and splitting in older concrete structures. The expansion of corrosion
products (iron oxide) of carbon steel reinforcement structure may induce mechanical
stress that can cause the formation of cracks and disrupt the concrete structure. If the
rebars have been poorly installed and are located too close to the concrete surface in
contact with the air, concrete spalling can easily occur: flat fragments of concrete are
detached from the concrete bars by the rebars corrosion and may fail down.
One of the main components of this corrosion protection is provided by the amount of
concrete cover protecting the steel. As a thumb rule, one inch of the cover is required
to protect the rebars. In other words, no rebar should be nearer than one inch of the
concrete surface.
3.
CHEMICAL DAMAGE
A. Carbonation
Carbon dioxide in the air can react with the calcium hydroxide in the concrete to
form calcium carbonate. This process is called carbonation which is essentially
the reversal of chemical process of calcination of lime taking place in the
B. Chlorides
Chlorides particularly calcium chloride, have been used to shorten the setting
time of concrete. However calcium chloride and (to a lesser extend) sodium
chloride have been shown to leach calcium hydroxide and cause chemical
changes in Portland cement leading to loss of strength as well as attacking the
steel reinforcement present in most concrete.
A totally different cause of concrete spalling is often found along the Australian
coastline. Coastal air is laden with chloride ion (from seawater salt). As concrete
is porous, it readily allows chloride ions to move easily through the concrete
matrix and from incipient anodes on the surface of the steel rebars, causing
nodules of rust on the steel surface. Even though the concrete may have a high
alkalinity, the surface passivation of the steel is disrupted by the chloride ions.
The rust nodules create internal stresses in the concrete, which results in crack in
the concrete around the affected steel. The cracks expose the rebar to more
chloride ion attack and more corrosion exacerbating the spalling problem.
C. Sulphates
Sulphates in solution in contact with concrete can cause chemical changes to the
cement, which can cause many microstructural effects on leading to the
weakening of cement binder. Sulphates and sulphites are ubiquitous in the
natural environment and are present from many sources, including gypsum
(calcium sulphate) often present as an additive in blended cement which
include fly ask and other sources of sulphate. With the notable exception of
barium sulphate, most sulphates are slightly to highly soluble in water. These
include acid rain where sulphur dioxide in the air shed is dissolved in rainfall to
produce sulphurous acids. In lightning storms, dioxide is oxidised into trioxides
making the residual sulphuric acid in the rainfall even more acidic. Local
government infrastructure is mostly corroded by sulphate arising from the
oxidation of sulphide which occurs when bacteria (for example in sewer mains)
reduce the ever present hydrogen sulphide gas to a film of sulphide (S-) or
disulphide (HS-) ions. This reaction is reversible, both either readily oxidising
on exposure to air or oxygenated storm water, to produce sulphate or sulphite
ions and acidic hydrogen ion in the reaction
HS- + H2O + O2 2H+ + SO4-.
The corrosion often present in the crown (top) of the sewer is directly
attributable to the process known as crown corrosion.
D. Leaching
When water flows through cracks present in concrete, water may dissolve
various minerals present in the hardened cement paste or in the aggregate if the
solution is unsaturated with respect to them. Dissolved ions such as calcium
(Ca2+) are leached out and transported in solutions some distance. If the physicochemical conditions prevailing in the seeping water evolve with distance along
the water path and water becomes supersaturated with respect to certain
minerals, they can further precipitate, making deposits or efflorescence inside
the cracks, or at the concrete outer surface. This process can cause the selfhealing of fractures in previous condition.
E. Decalcification
Distilled water can wash out calcium content in concrete, leaving the concrete in
brittle condition. A common source of distilled water can be condensed steam.
Distilled water washes out the calcium because normal water will already
contain some calcium ions, which will not dissolve them.
F. Seawater
Concrete exposed to sea water is susceptible to its corrosive effects. The effects
are more pronounced above the tidal zone than where the concrete is
permanently submerged. In the submerged zone magnesium and hydrogen
carbonate ions precipitate a layer of brucite, about 30 micrometres thick, on
which a slower deposition of calcium carbonate as aragonite occurs. These
layers somewhat protect the concrete from other processes, which include attack
by magnesium, chloride and sulphate ions and carbonation. Above the water
surface, mechanical damage may occur by erosion by waves themselves or by
sand and gravel the carry, and by crystallisation of salts from water soaking into
the concrete pores and then drying up. Pozzolanic cement and cements using
more than 60% of slag as aggregate are more resistant to seawater than pure
Portland cement. Seawater corrosion contains elements of both chlorides and
sulphate corrosion.
4. BACTERIAL CORROSION
5. PHYSICAL DAMAGE
6. THERMAL DAMAGE