Reinforcement corrosion-induced cover cracking and its time prediction for reinforced concrete structures

A relation between the radial pressure induced by expansion corrosion products and weight loss percentage of corroded steel was developed and simplified by investigating the influence of the mechanical properties of corrosion layer on cover cracking. By taking account of the penetration of the rusts into open cracks, a mathematical model that predicts the cover cracking time was proposed based on Faraday’s law. Some experimental observations were compared with the predictions made by the proposed model and two existing models, which indicates that the presented model is more suitable for predicting cracking time for both accelerated and long-term corrosion conditions.

► The influence of rusts properties on cover cracking is neglected when Er > 1 GPa.
► Penetration of corrosion products into the corrosion cracks is taken into account.
► The filling extent of rusts within the cracks depends on corrosion conditions.
► The proposed model has high accuracy in predicting the cover cracking time.
► Faraday’s law is more suitable in evaluating the buildup of corrosion products.