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In corrosion, spalling occurs when a substance (metal or concrete) sheds tiny particles of corrosion products as the corrosion reaction progresses. Although they are not soluble or permeable, these corrosion products do not adhere to the parent material's surface to form a barrier to further corrosion, as happens in passivation .
Example of flat piece of concrete having dislodged with corroded rebar underneath, Welland River bridge across Queen Elizabeth Way in Niagara Falls, Ontario. The expansion of the corrosion products (iron oxides) of carbon steel reinforcement structures may induce internal mechanical stress (tensile stress) that cause the formation of cracks and disrupt the concrete structure.
Alkali–aggregate reaction is a term mainly referring to a reaction which occurs over time in concrete between the highly alkaline cement paste and non-crystalline silicon dioxide, which is found in many common aggregates. This reaction can cause the expansion of the altered aggregate, leading to spalling and loss of strength of concrete.
All concrete structures will crack to some extent, due to shrinkage and tension. Concrete which is subjected to long-duration forces is prone to creep. The density of concrete varies, but is around 2,400 kilograms per cubic metre (150 lb/cu ft). [1] Reinforced concrete is the most common form of concrete.
The mechanical stresses induced by the thermal cycles create micro-cracks in the concrete matrix and so facilitate the accessibility to water of the reactive mineral phases in the treated samples. [48] The concrete microbar test was proposed by Grattan-Bellew et al. (2003) as a universal accelerated test for alkali-aggregate reaction. [49]
Concrete spalling from the ceiling of an office unit (interior) in Singapore, possibly due to rebar corrosion. Reinforced concrete can fail due to inadequate strength, leading to mechanical failure, or due to a reduction in its durability. Corrosion and freeze/thaw cycles may damage poorly designed or constructed reinforced concrete.