Bridging the Gap: Assessing Material Performance of Laboratory Specimens and Concrete Structures.

Chloride ingress and carbonation pose a significant risk of steel rebar corrosion in concrete structures. Various models exist to simulate the initiation phase of rebar corrosion, addressing both carbonation and chloride ingress mechanisms separately. These models also consider the environmental loads and material resistances, typically determined through laboratory testing based on specific standards. However, recent findings show significant differences between material resistances obtained from standardized laboratory specimens and those extracted from real structures, with the latter exhibiting inferior performance on average. To address this issue, a comparative study was conducted between laboratory specimens and on-site test walls or slabs, all cast using the same concrete batch. This study encompassed five construction sites featuring different concrete compositions. While laboratory specimens adhered to European curing standards, the walls were subjected to formwork curing for a predetermined period (typically 7 days) to simulate practical conditions. In some instances, a portion of the test walls/slabs received only one day of surface curing to emulate inadequate curing conditions. Subsequent testing of compressive strength and resistance to chloride ingress revealed that field specimens exhibited lower material resistance compared to their laboratory counterparts. This trend was also observed in the modulus of elasticity and carbonation rate. Notably, shorter curing periods further compromised performance, particularly resistance to chloride ingress and carbonation. These findings highlight the importance of establishing acceptance criteria not only for concrete delivered to construction sites but also for ensuring the quality of the actual structure.

Diffusion potentials in saturated hardened cement paste upon chloride exposure.

The diffusion potentials can cause significant errors in corrosion-related investigations of reinforced concrete structures (half-cell potential mapping, potentiometric sensors). Therefore, an improved understanding of the diffusion potentials in cement-based materials is needed. This study investigates the permselective behavior and its implication for the arising diffusion potentials. A diffusion cell is used to study the diffusion potentials in hardened cement pastes with imposed NaCl gradients. The cement pastes consist of ordinary Portland cement (OPC) and blast furnace cement (BFC) with water-cement ratios of 0.30-0.70. Laser ablation inductively coupled plasma mass spectrometry (LA-ICP-MS) is used to determine the concentration profiles of Cl, Na, K and Ca in the cement pastes with a high spatial resolution (100 µm). For the BFC pastes, considerable differences in the Cl- and Na+ mobilities are found, indicating their permselective behavior. Despite the permselective behavior, the measured diffusion potentials are small (- 6 to + 3 mV) for all investigated cement pastes due to the high pH levels (13-14) in the pore solutions. However, when using the diffusion cell, the pH differences interfere with the measured diffusion potentials. The interfering pH differences need to be considered for an accurate measurement of the diffusion potentials in cement pastes.

On the Chloride Distribution in Concrete and Mortar Samples after an RCM Test.

It is of essential need to face the challenges of CO2 reduction in industrial cement and concrete production reliable test methods in order to evaluate the performance of concretes, especially with regard to the service life of our infrastructure. The rapid chloride migration test (RCM test) is a standard method to assess the resistance against chloride ingress of concrete. However, during our study, certain critical questions arose with regard to the chloride distribution. The sharp chloride ingress front based on the model assumptions contradicted the shallow gradient of the experimental data. For this reason, investigations on chloride distribution in concrete and mortar samples after RCM tests were performed. The focus was on the factors influencing the extraction, e.g., time after RCM test and the location on sample. Furthermore, differences between concrete and mortar samples were investigated. The investigations showed that no sharp gradient on concrete samples was found due to the extremely uneven chloride front. In contrast, the theoretical profile shape was instead demonstrated on mortar specimens. The prerequisite for this result is that the drill powder must be taken directly after the completion of the RCM test from very uniform penetration areas. Thus, the model assumptions on the chloride distribution via the RCM test could be confirmed.

Impact of External Mechanical Loads on Coda Waves in Concrete.

During their life span, concrete structures interact with many kinds of external mechanical loads. Most of these loads are considered in advance and result in reversible deformations. Nevertheless, some of the loads cause irreversible, sometimes unnoticed changes below the macroscopic scale depending on the type and dimension of the impact. As the functionality of concrete structures is often relevant to safety and society, their condition must be known and, therefore, assessed on a regular basis. Out of the spectrum of non-destructive monitoring methods, Coda Wave Interferometry using embedded ultrasonic sensors is one particularly sensitive technique to evaluate changes to heterogeneous media. However, there are various influences on Coda waves in concrete, and the interpretation of their superimposed effect is ambiguous. In this study, we quantify the relations of uniaxial compression and uniaxial tension on Coda waves propagating in normal concrete. We found that both the signal correlation of ultrasonic signals as well as their velocity variation directly reflect the stress change in concrete structures in a laboratory environment. For the linear elastic range up to 30% of the strength, we calculated a velocity variation of -0.97‱/MPa for compression and 0.33%/MPa for tension using linear regression. In addition, these parameters revealed even weak irreversible changes after removal of the load. Furthermore, we show the time-dependent effects of shrinkage and creep on Coda waves by providing the development of the signal parameters over time during half a year together with creep recovery. Our observations showed that time-dependent material changes must be taken into account for any comparison of ultrasonic signals that are far apart in time. The study's results demonstrate how Coda Wave Interferometry is capable of monitoring stress changes and detecting even small-size microstructural changes. By indicating the stated relations and their separation from further impacts, e.g., temperature and moisture, we anticipate our study to contribute to the qualification of Coda Wave Interferometry for its application as an early-warning system for concrete structures.

Computational Generation of Virtual Concrete Mesostructures.

Concrete is a heterogeneous material with a disordered material morphology that strongly governs the behaviour of the material. In this contribution, we present a computational tool called the Concrete Mesostructure Generator (CMG) for the generation of ultra-realistic virtual concrete morphologies for mesoscale and multiscale computational modelling and the simulation of concrete. Given an aggregate size distribution, realistic generic concrete aggregates are generated by a sequential reduction of a cuboid to generate a polyhedron with multiple faces. Thereafter, concave depressions are introduced in the polyhedron using Gaussian surfaces. The generated aggregates are assembled into the mesostructure using a hierarchic random sequential adsorption algorithm. The virtual mesostructures are first calibrated using laboratory measurements of aggregate distributions. The model is validated by comparing the elastic properties obtained from laboratory testing of concrete specimens with the elastic properties obtained using computational homogenisation of virtual concrete mesostructures. Finally, a 3D-convolutional neural network is trained to directly generate elastic properties from voxel data.

Reduced Order Multiscale Simulation of Diffuse Damage in Concrete.

Damage in concrete structures initiates as the growth of diffuse microcracks that is followed by damage localisation and eventually leads to structural failure. Weak changes such as diffuse microcracking processes are failure precursors. Identification and characterisation of these failure precursors at an early stage of concrete degradation and application of suitable precautionary measures will considerably reduce the costs of repair and maintenance. To this end, a reduced order multiscale model for simulating microcracking-induced damage in concrete at the mesoscale level is proposed. The model simulates the propagation of microcracks in concrete using a two-scale computational methodology. First, a realistic concrete specimen that explicitly resolves the coarse aggregates in a mortar matrix was generated at the mesoscale. Microcrack growth in the mortar matrix is modelled using a synthesis of continuum micromechanics and fracture mechanics. Model order reduction of the two-scale model is achieved using a clustering technique. Model predictions are calibrated and validated using uniaxial compression tests performed in the laboratory.

Penetration of Cement Pastes into Particle-Beds: A Comparison of Penetration Models.

For the selective paste intrusion (SPI) method, thin layers of aggregate are locally bound by cement paste where the structure shall arise. After completion of the printing process, the structure is excavated from the particle-bed and the unbound particles are removed. However, for a sufficient layer bonding and shape accuracy, the rheology of the cement paste must be adapted to the flow resistance of the particle-bed. For practical application, that means mostly time and material consuming "trial and error" tests. To prevent that, analytical models can help to predict the penetration of the cement paste. This paper presents four analytical models to calculate the penetration depth of a cement paste into a particle packing. Based on Darcy's law, an already existing model is slightly modified (model A+) and a generalized (model C), an advanced generalized (model D) as well as a simplified model (model B/B+) are developed. Compared to conducted tests on the penetration depth, model B showed good accuracy (deviation <1.5 mm) for pastes with a yield stress ≥8.2 Pa, model A+/B+/C for ≥ 5.4 Pa and model D even for <5.4 Pa. Finally, an application guide for each model for practical use will be given.

Particle-Bed Binding by Selective Paste Intrusion-Strength and Durability of Printed Fine-Grain Concrete Members.

The selective paste intrusion (SPI) describes a selective binding, additive manufacturing method. SPI bonds thin layers of aggregate by cement paste locally. Currently, SPI can achieve higher compressive strength, durability, and easier unpacking behavior compared to other selective binding methods suitable for the production of concrete structures. Particle-bed based methods not only achieve much higher surface resolutions than depositing (extrusion)-based additive manufacturing methods but also have no restrictions in freedom of form. However, the mechanical performance of SPI components strongly depends on the void content between the individual layers and thus the penetration behavior of the cement paste. This paper presents direction-dependent measurements of the strength and durability of SPI-printed components compared to casted specimens with the same mixing composition. The results show compressive strength values between 70 and 78 MPa after 7 d, flexural strength of 1/10 without reinforcement, a high freeze-thaw resistance, no detectable carbonation after 182 days of exposure under ambient CO2-conditions, and after 28 days under increased CO2 content of 2 vol % as well as low chloride penetration resistances. All tests showed in almost all cases no dependency on the layer orientation.

Interlayer Reinforcement Combined with Fiber Reinforcement for Extruded Lightweight Mortar Elements.

Lightweight mortar extrusion enables the production of monolithic exterior wall components with improved thermal insulation by installing air chambers and reduced material demand compared to conventional construction techniques. However, without reinforcement, the systems are not capable of bearing high flexural forces and, thus, the application possibilities are limited. Furthermore, the layer bonding is a weak spot in the system. We investigate a reinforcement strategy combining fibers in the mortar matrix with vertically inserted elements to compensate the layer bonding. By implementing fibers in the extruded matrix, the flexural strength can be increased almost threefold parallel to the layers. However, there is still an anisotropy between the layers as fibers are oriented during deposition and the layer bond is still mainly depending on hydration processes. This can be compensated by the vertical insertion of reinforcement elements in the freshly deposited layers. Corrugated wire fibers as well as short steel reinforcement elements were suitable to increase the flexural strength between the layers. As shown, the potential increase in flexural strength could be of a factor six compared to the reference (12 N/mm2 instead of 1.9 N/mm2). Thus, the presented methods reduce anisotropy in flexural strength due to layered production.

Modeling SAOS Yield Stress of Cement Suspensions: Microstructure-Based Computational Approach.

Two static yield stress models, one known as YODEL and the newly proposed BreakPro, based on inter-particle bond breaking probability, were employed to comparatively simulate the yield stress of cement suspensions, induced by oscillatory rheological tests with small amplitude oscillatory shear (SAOS). This yield stress occurs at a critical strain in the order of 0.01%, and is commonly attributed to the limit of the linear viscoelastic domain, where attractive forces bridge the cement particles and form a flocculated particle network. YODEL is based on van der Waals (vdW) interaction forces to describe the yield stress for flow onset at a critical strain of a few percent, developed for simple non-reactive particulate suspensions. However, due to the high pH and reactivity of cementitious suspensions, their particle interaction forces are much higher than vdW. Therefore, until now, the YODEL adaptations to cementitious suspensions did not explicitly consider the microstructural-based salient feature of the original model, but used it as an implicit fitting parameter to scale the average attractive force. In this paper, the force is inversely estimated using the full power of the two microstructural-based models, presenting a new mathematical tool for investigating the fragility of the rigid percolated structure of cement suspensions. The model parameters were calibrated on measured yield stresses obtained by SAOS measurements in a high-sensitivity rheometer. The estimated forces were found to be 5.57 (BreakPro) and 1.43 (YODEL) times higher than typical van der Waals forces. The YODEL percolation threshold of 21% turned out to be significantly lower than the one found by the BreakPro model (37%). This indicated that BreakPro modeling assumptions are better suited for the description of yield stress at SAOS critical strain than the YODEL model.

Effect of Pre-Shear on Agglomeration and Rheological Parameters of Cement Paste.

Cementitious pastes are multiphase suspensions that are rheologically characterized by viscosity and yield stress. They tend to flocculate during rest due to attractive interparticle forces, and desagglomerate when shear is induced. The shear history, e.g., mixing energy and time, determines the apparent state of flocculation and accordingly the particle size distribution of the cement in the suspension, which itself affects suspension's plastic viscosity and yield stress. Thus, it is crucial to understand the effect of the mixing procedure of cementitious suspensions before starting rheological measurements. However, the measurement of the in-situ particle agglomeration status is difficult, due to rapidly changing particle network structuration. The focused beam reflectance measurement (FBRM) technique offers an opportunity for the in-situ investigation of the chord length distribution. This enables to detect the state of flocculation of the particles during shear. Cementitious pastes differing in their solid fraction and superplasticizer content were analyzed after various pre-shear histories, i.e., mixing times. Yield stress and viscosity were measured in a parallel-plate-rheometer and related to in-situ measurements of the chord length distribution with the FBRM-probe to characterize the agglomeration status. With increasing mixing time agglomerates were increasingly broken up in dependence of pre-shear: After 300 s of pre-shear the agglomerate sizes decreased by 10 µm to 15 µm compared to a 30 s pre-shear. At the same time dynamic yield stress and viscosity decreased up to 30% until a state of equilibrium was almost reached. The investigations show a correlation between mean chord length and the corresponding rheological parameters affected by the duration of pre-shear.

L-Box Form Filling of Thixotropic Cementitious Paste and Mortar.

Rheological properties of cementitious pastes and mortar affect the casting, placement, and setting properties of fresh concrete. Fundamental rheological knowledge thus helps in predicting concrete flowability and workability. Empirical equations correlate actual rheological parameters based on physical material characteristics to workability tests. Still, these equations generally only take the dynamic yield stress of the material into account. This is not sufficient for thixotropic cementitious pastes or mortars, which possess structural buildup at rest. Workability predictions regarding the flow of concrete are thus more complicated with thixotropic materials. During form-filling in L-shaped formworks, the flow velocity of concrete slows down, wherefore rheological parameters change with time. At initial fast flow, high shear rates without structural buildup can be assumed. Dynamic yield stress and a steady state viscosity thus are proper parameters for empirical equations describing concrete flowability. During low shear rates, partial structural buildup takes place. Viscosity and yield stress increase due to agglomeration and affect the flowability of concrete tremendously. Rheological parameters of various cementitious pastes and mortars varying in their solid volume fraction and flowability were investigated in a vane-in-cup rheometer. The workability of the same mixtures was investigated by measuring the flow length in an L-shaped formwork. The effect of yield stress, viscosity, and thixotropic structural buildup on flow length was investigated. Subsequently correlations and discrepancies between flowability parameters and workability equations were analyzed.