In this work, non-linear ultrasonic wave techniques have been used to detect the onset of micro-cracking due to steel corrosion in model reinforced concrete elements. The specimens were of prismatic shape with a single steel rebar. The corrosion was forced by admixing an appropriate amount of sodium chloride at the moment of preparing the concrete mix, and by the application of an electric field, using a constant current density power source, and making the steel rebar work as the anode, and an external counter-electrode as the cathode. The preliminary results indicate that the onset of cracking seems to be accompanied by the appearance of higher-harmonic generation at the output signal (harmonic distortion), when the system is excited by the means of an ultrasound wave with a burst central frequency. Other phenomena related to the micro-cracks induced by corrosion, such is the parametric generation with respect to the fundamental amplitude, have not been observed until now.

This work presents results allowing an unequivocal correlation of the observations of strong nonlinear elastic features of ultrasonic waves (values of the nonlinearity parameters exceeding the thresholds corresponding to undamaged states), with the critical events of the corrosion-induced surface cracking of reinforced cement-mortar specimens. These observations point to the possibility of the early detection of cracking using nonlinear ultrasonic (NLU) techniques. Experimental evidence is presented on the existence of active net mass transport processes, due to wick action, in the course of the corrosion tests, in the experimental conditions of this work. These phenomena might explain the observed abrupt shifting of the nonlinear parameter values (typically increasing and then decreasing post-peak, even reaching values typical of the undamaged state), and, partially, the high variability obtained for the values of the nonlinear parameters in damaged (cracked) states. Finally, some consequences are derived from the point of view of use of the NLU techniques in engineering practice, i.e., in surveys aimed at evaluating reinforced concrete structures affected by corrosion.

This article shows the research carried out by the authors focused on how the shape of structural reinforced concrete elements treated with electrochemical chloride extraction can affect the efficiency of this process. Assuming the current use of different anode systems, the present study considers the comparison of results between conventional anodes based on Ti-RuO₂ wire mesh and a cement-based anodic system such as a paste of graphite-cement. Reinforced concrete elements of a meter length were molded to serve as laboratory specimens, to closely represent authentic structural supports, with circular and rectangular sections. Results confirm almost equal performances for both types of anode systems when electrochemical chloride extraction is applied to isotropic structural elements. In the case of anisotropic ones, such as rectangular sections with no uniformly distributed rebar, differences in electrical flow density were detected during the treatment. Those differences were more extreme for Ti-RuO₂ mesh anode system. This particular shape effect is evidenced by obtaining the efficiencies of electrochemical chloride extraction in different points of specimens.

Reinforced concrete structure durability hinges on concrete permeability, which relies on the characteristics of the inner porous network. Harmful ions and gases can accelerate steel corrosion. Permeability-reducing admixtures (PRA), including crystalline admixtures (CA), are commonly used to mitigate this. This study examines a commercial CA’s impact on durability-related aspects in concrete specimens. Two concrete mixtures with matching proportions were prepared: a reference mix and another mix with a commercial crystalline admixture. Several properties were studied, such as compressive strength, density, porosity, electrical resistivity, water absorption capacity, chloride diffusion, air permeability, and corrosion resistance. The studied admixture in concrete yields several positive outcomes such as a slight reduction in mixing water, a potential 6% increase in concrete’s compressive strength and the development of a denser and less permeable structure with 3% lower porosity and water absorption than the reference mix. Electrical resistivity improves by 10%. Unidirectional chloride diffusion tests show no differences. Air permeability decreases by from 36% to 55%, and the water absorption rate diminishes by 23%. The admixture potentially reduces the scatter in corrosion initiation periods for steel reinforcements, delaying corrosion onset by around 60 days, although more extensive experiments are needed for definitive conclusions.

An electrochemical model is presented to calculate the rebar shape time-evolution in reinforced mortar specimens during forced corrosion tests. This provides a more realistic description than the usually used geometric models. The current distribution along the rebar perimeter is calculated by using Finite Element Method (FEM) to solve Laplace equation. Then, Faraday’s law is used to relate current distribution to rebar volume increase due to corrosion products creation. The shape of the rebar section is obtained as a function of corrosion time.