Sulfate Attack on Concrete - Chapter 0 docx

Contents Preface Acknowledgments 1 Introduction References 2 Chemistry and physics of cement paste 2.1 Concrete components 2.1.1 Hydraulic cements 2.1.2 Aggregates 2.1.3Mineral and chemi

Sulfate Attack on Concrete

Modern Concrete Technology Series

A series of books presenting the state-of-the-art in concrete technology Series Editors

National Building Research Institute Office of the President

Technion–Israel Institute of Technology University of British Colombia

1 Fibre Reinforced Cementitious Composites

A Bentur and S Mindess

2 Concrete in the Marine Environment

P.K Mehta

3 Concrete in Hot Environments

I Soroka

4 Durability of Concrete in Cold Environments

M Pigeon and R Pleau

5 High Performance Concrete

P.-C Aïtcin

6 Steel Corrosion in Concrete

A Bentur, S Diamond and N Berke

7 Optimization Methods for Material Design of Cement-based Composites

Edited by A Brandt

8 Special Inorganic Cements

I Odler

9 Concrete Mixture Proportioning

F de Larrard

10 Sulfate Attack on Concrete

J Skalny, J Marchand and I Odler

11 Determination of Pore Structure Parameters

K Aligizaki

12 Fundamentals of Durable Reinforced Concrete

M.G Richardson

Sulfate Attack on Concrete

Jan Skalny, Jacques Marchand and Ivan Odler

London and New York

First published 2002 by Spon Press

11 New Fetter Lane, London EC4P 4EE

Simultaneously published in the USA and Canada

by Spon Press

29 West 35th Street, New York, NY 10001

Spon Press is an imprint of the Taylor & Francis Group

© 2002 Jan Skalny, Jacques Marchand and Ivan Odler

All rights reserved No part of this book may be reprinted or reproduced or utilised in any form or by any electronic,

mechanical, or other means, now known or hereafter

invented, including photocopying and recording, or in any

information storage or retrieval system, without permission in writing from the publishers

The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors

or omissions that may be made

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library

Library of Congress Cataloging in Publication Data

A catalogue record has been requested

ISBN 0–419–24550–2

This edition published in the Taylor & Francis e-Library, 2003.

ISBN 0-203-30162-5 Master e-book ISBN

ISBN 0-203-34224-0 (Adobe eReader Format)

(Print Edition)

Contents

Preface

Acknowledgments

1 Introduction

References

2 Chemistry and physics of cement paste

2.1 Concrete components

2.1.1 Hydraulic cements

2.1.2 Aggregates

2.1.3Mineral and chemical admixtures

2.1.4 Water

2.2 Hydration of Portland clinker-based cements 2.2.1 Chemistry of hydration reactions

2.3Hydrated cement paste, mortar and concrete 2.3.1 Microstructural development

2.3.2 Development of physical properties

References

3 Concrete deterioration

3.1 Principal causes of concrete deterioration

3.1.1 Deterioration caused by dissolution of paste components

3.1.2 Deterioration caused by ingress of external chemicals

3.1.3 Expansive reactions with aggregate

3.1.4 Frost-related deterioration

3.1.5 Corrosion of embedded steel

3.1.6 Abrasion, erosion and cavitation

3.2 Selection of materials

3.2.1 Importance of mix design

3.3 Concrete processing

3.3.1 Mixing, curing, placing, finishing, and maintenance

3.4 Effect of environmental exposure

3.4.1 Effect of chemical environment

3.4.2 Effects of temperature and humidity

changes 3.5 Known prevention techniques

References

4 Sulfate attack

4.1 Forms of sulfate attack

4.1.1 Manifestations of sulfate attack

4.2 Source of sulfates in sulfate attack

4.2.1 Internal sources

4.2.2 External sources

4.3Mechanisms of sulfate-related deterioration

4.3.1 Sulfate attack mechanisms – a brief history 4.4 Types of expansive reactions

4.4.1 Increase of the solid volume

4.4.2 Expansion in a topochemical reaction 4.4.3Oriented crystal growth

4.4.4 Expansion caused by crystallization pressure 4.4.5 Expansion caused by swelling phenomena 4.4.6 Other expansive processes

4.5 Ettringite formation and expansion

4.6 Other forms of sulfate-related expansion

4.7 Interaction of sulfates with the C-S-H phase

4.8 Internal sulfate attack

4.8.1 Internal sulfate attack at ambient temperature 4.8.2 Heat-induced sulfate attack or DEF

4.8.3Concluding comments on internal

sulfate attack 4.9 External sulfate attack

4.9.1 Na 2 SO 4 and K 2 SO 4

4.9.2 CaSO 4

4.9.3MgSO 4

4.9.4 H 2 SO 4

4.9.5 (NH 4 ) 2 SO 4

4.9.6 Sulfate attack in the presence of SiO 2

and CO 2 4.9.7 Sea water

4.9.8 Concluding comments on external

sulfate attack

4.10 Sulfate resistant cements – mechanism of action

4.11 Physical sulfate attack or salt crystallization

4.12 Bacteriogenic corrosion of concrete in waste

water networks

4.13Conditions affecting sulfate attack

References

5 Consequences of sulfate attack on concrete

5.1 Introduction

5.2 External appearance and volume stability of concrete attacked by sulfate

5.2.1 External appearance and volume stability of concrete subjected to internal sulfate attack

5.2.2 External appearance and volume stability of concrete subjected to external sulfate attack

5.3Consequences of sulfate attack on the microstructure

of concrete

5.4 Consequences of sulfate attack on the mechanical

properties of concrete

5.5 Concluding remarks

References

6 Prevention of sulfate attack

6.1 Introduction

6.2 Measures to protect concrete against composition-induced internal sulfate attack

6.3Measures to protect concrete against heat-induced internal sulfate attack

6.4 Measures to protect concrete against external

sulfate attack

6.5 Concluding remarks

References

7 Modeling of deterioration processes

7.1 Introduction

7.2 Microstructure-based performance models

7.2.1 Empirical models

7.2.2 Mechanistic models

7.2.3Numerical models

7.3Concluding remarks

Note

References

8 Cas e hi s tori es

8.1 Deterioration of residential buildings in Southern California 8.2 Sulfate attack damage brought about by heat

treatment (DEF)

8.3Concrete railroad sleepers: heat-induced internal

sulfate attack (DEF) or ASR?

8.4 Deterioration of UK concrete bridge foundations caused

by the thaumasite form of sulfate attack (TSA)

Acknowledgments

Notes

References

9 Assessment of cement and concrete performance under sulfate attack

9.1 Prescriptive standards for assessing sulfate resistance

of cements

9.2 Prescriptive standards for concrete to be exposed to

sulfate attack

9.3Performance standards

References

Concluding remarks

Preface

We consider it to be a great honor to be chosen by Professors A Bentur and

S Mindess to prepare this book for publication by Spon Press and it was not without trepidation that we accepted the task to summarize the available knowledge on the effect of sulfates on concrete We were hesitant because the mechanistic issues of sulfate attack on concrete are complex and sometimes controversial

The multidimensionality of the sulfate attack issues becomes obvious when one realizes the variability of the environmental conditions under which concrete is used, of the complex chemistry and mineralogy of the con-crete components, and of the less-than-well-defined processing conditions used in making concrete to be used in a variety of structures In discussing sulfate attack mechanisms, one has to deal, among others, with issues of chemical and mineralogical composition of the aggressive species, properties

of amorphous to crystalline reaction products, variability and limited con-trollability of the reaction (curing) conditions, and to consider difficult issues related to best testing methodology, standardization, prediction of service life by modeling, etc All the above make consolidation of the existing know-ledge a considerable challenge

The book is prepared for an audience consisting of students of materials engineering, construction practitioners, and researchers As the loss of dur-ability of concrete almost always involves chemical and physico-chemical processes, it may be difficult for some readers to follow the intricate details

of sulfate attack mechanisms To overcome this, we included a few chapters summarizing the basics of cement hydration and concrete deterioration It is entirely possible that for some, the book contains excessive information; others may consider the given details to be inadequate There will be voices disagreeing with our interpretation of the “average” literature data To these

we can only say that we did our best to consolidate the available data in an understandable manner and we suggest that, if needed, the readers visit the references given at the end of each chapter

We hope that this book will be considered a good introduction to the scientific and practical intricacies of sulfate attack mechanisms, as well as becoming an impetus to younger researchers to develop a romance with engineering materials.

Acknowledgments

The authors would like to thank the numerous colleagues who helped in realizing this complex project First of all, we would like to acknowledge the invitation by Professors A Bentur and S Mindess, the Editors of this Spon Press series of books on concrete technology, to prepare this manuscript for publication Although an honor, the consolidation of all the available controversial data was not without difficulties and frus-trations

We are most thankful to Messrs P.W Brown, S Diamond, J Gebauer,

V Johansen, B Mather, K.L Scrivener, H.F.W Taylor, N Thaulow,

M Thomas and unnamed others for most useful and critical discussions

on mechanistic aspects of various forms of sulfate attack We would like

to acknowledge our gratefulness to J.J Beaudoin, N.J Crammond,

S Diamond, G Frohnsdorff and E.M Gartner for their critical review of parts of the manuscript, and to N.J Crammond and coworkers for con-tributing the case study on thaumasite Special in memoriam thanks are

due to C.D Lawrence who made us available his unpublished bibliography

of “DEF” literature and J Jambor who left with us his unpublished report

on sulfate attack

We would also like to acknowledge the authors of the high-quality photographic material used throughout the book (obtained from Messrs

M Alexander, S Badger, C Fourie, U Hjorth Jakobsen, S Sahu, P Stutzman,

N Thaulow and M Thomas), as well as photographic and other material obtained from CEMBUREAU (Belgium), G.M Idorn Consult (Denmark), BRE – Building Research (United Kingdom), R.J Lee Group (USA), The Erlin Company (USA), Portland Cement Association (USA), and other sources Our thanks are also due to J Parent (Laval University, Quebec, Canada) for preparation of the graphic material

Our deep thanks are due to the staff of Spon Press, specifically Marie-Louise Logan and Richard Whitby, for their dedicated work and profession-alism Finally, important thanks are also due to our spouses – Magdalena,

Marie-Helene and Marika – for exercising patience that some of us cannot reciprocate with

Jan Skalny (jpskalny@aol.com) Jacques Marchand (jacques.marchand@gci.ulaval.ca)

Ivan Odler (ivanodler@aol.com)

January 2001