Finite element modeling of concrete cover cracking due to non-uniform steel corrosion

•A coupled diffusion-mechanical model was presented in this paper.•Non-uniform corrosion distribution around the steel was considered.•Cracking mechanisms of concrete cover due to steel corrosion under different boundary conditions were examined.•Non-uniform corrosion around the steel results in larger crack width compared to uniform corrosion under the same amount of steel loss.

Steel corrosion in reinforced concrete structures can lead to cracking of concrete cover when corrosion products expand. In this study, a finite element model has been developed to study crack propagation in concrete as corrosion progresses. The model considers the practical situation of chloride penetration from the member surface, which leads to non-uniform corrosion distribution around the steel cross section. To highlight the necessity to consider non-uniform corrosion in practical situations, the evolution of crack width under non-uniform corrosion for concrete with different boundary conditions is compared with that under uniform corrosion.