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Macroscopic voids at the steel-concrete interface and their degree of saturation with an aqueous electrolyte are known to play an important role in the corrosion of steel in reinforced concrete. Irrespective of the exposure conditions and testing parameters, corrosion products have been reported to consistently precipitate in a unique pattern within these macroscopic voids, preferentially along the void walls and growing inward. The underlying mechanisms governing corrosion product precipitation in macroscopic voids and their effects on long-term durability remain unclear. Through in-situ X-ray computed tomography observations, thermodynamic and kinetic considerations, and numerical modelling of water transport within macroscopic voids, here, we provide plausible hypotheses of the processes responsible for the precipitation of corrosion products along the walls of the voids. Understanding the mechanisms of corrosion product precipitation can offer insights into the development of stresses in and around the macroscopic interfacial void and the durability of reinforced concrete structures. This contribution also discusses opportunities for different avenues for research to elucidate several multiscale processes that influence the durability of reinforced concrete.

We introduce an experimental setup to chemically image corrosion processes at metal-electrolyte interfaces under stagnant, confined conditions relevant in a wide range of situations. The setup is based on a glass capillary, in which precipitation of corrosion products in the interfacial aqueous phase can be monitored over time with optical microscopy, and chemically and structurally characterized with microscopic synchrotron-based techniques (X-ray fluorescence, X-ray diffraction, and X-ray absorption spectroscopy). Moreover, quantification of precipitates through X-ray transmission measurements provides in-situ corrosion rates. We illustrate this setup for iron corrosion in a pH 8 electrolyte, revealing the critical role of O2 and iron diffusion in governing the precipitation of ferrihydrite and its transformation to goethite. Corrosion and coupled reactive transport processes can thus be monitored and fundamentally investigated at the metal-electrolyte interface, with micrometer-scale resolution. This capillary setup has potential applications for in-situ corrosion studies of various metals and environments.

Accurate model predictions of corrosion-driven damage in reinforced concrete structures necessitate a comprehensive understanding of the rate of corrosion product formation. Here, we investigate the influence of dissolved Si characteristic of cementitious systems on the rate of corrosion product transformation at alkaline pH. Compared to systems aged in the absence of Si, small amounts of Si retard the formation rate of the thermodynamically stable corrosion product goethite by a factor of 10. The estimated first order rate constant of transformation k decreases exponentially as a function of the dissolved Si concentration and follows the progression log10k = log10k_0 - 14.65[Si]^0.28. Findings further suggest that the observed retardation is primarily due to the formation of a mobile aqueous Fe-Si complex. The concentration of Si in cementitious systems has a crucial influence, and additional research is required to fully incorporate this factor into reactive transport models, ultimately essential for accurate service life predictions.

While it is widely accepted that the steel-concrete interface (SCI) plays an important role in governing the long-term durability of reinforced concrete structures, understanding about the primary features of the SCI that influence corrosion degradation mechanisms has remained elusive. This lack of knowledge can be attributed, on the one hand, to the complex heterogeneous nature of the SCI, and, on the other hand, the absence of experimental techniques suitable for studying the relevant features of the SCI. Here, we use focused ion beam - scanning electron microscopy (FIB-SEM) nanotomography to obtain high resolution 3D tomograms of the steel-concrete interfacial zone. Five tomograms, spanning volumes ranging from 8,000 to 200,000 cubic micrometer, were acquired for situations representative of both non-corroded and corroded SCIs. The achieved voxel size falls within the range of 30-50 nm, thus providing a resolution clearly surpassing the capabilities of computed X-ray tomography. This resolution enables the 3D characterization of the microstructure at the capillary scale, which is the scale at which relevant corrosion and related mass transport processes occur. Thus, FIB-SEM nanotomography is capable of yielding datasets of the SCI that serve as basis for the generation of digital twins of the interfacial microstructure, thereby enabling future studies about durability and corrosion of reinforced concrete at the pore scale.

Cathodic protection (CP) was introduced two centuries ago and since has found widespread application in protecting structures such as pipelines, offshore installations, and bridges from corrosion. Despite its extensive use, the fundamental working mechanism of CP remains debated, particularly for metals in porous media such as soil. Here, we offer resolution to the long-standing debate by employing in-situ and ex-situ characterisation techniques coupled with electrochemical measurements to characterise the spatio-temporal changes occurring at the steel-electrolyte interface. We show that upon CP, the interfacial electrolyte undergoes alkalinisation and deoxygenation, and that depending on polarisation conditions, an iron oxide film can simultaneously form on the steel surface. We further demonstrate that these changes in interfacial electrolyte chemistry and steel surface state result in altered anodic and cathodic reactions and their kinetics. We propose a mechanism of CP that integrates the long debated theories, based on both concentration and activation polarisation, complimentarily. Implications of this coherent scientific understanding for enhancing corrosion protection technologies and the safe, economic, and environmental-friendly operation of critical steel-based infrastructures are discussed.

The steel-concrete interface (SCI) is known to play a major role in corrosion of steel in concrete, but a fundamental understanding is still lacking. One reason is that concrete's opacity complicates the study of internal processes. Here, we report on the application of bimodal X-ray and neutron microtomography as in-situ imaging techniques to elucidate the mechanism of steel corrosion in concrete. The study demonstrates that the segmentation of the specimen components of relevance - steel, cementitious matrix, aggregates, voids, corrosion products - obtained through bimodal X-ray and neutron imaging is more reliable than that based on the results of each of the two techniques separately. Further, we suggest the combination of tomographic in-situ imaging with ex-situ SEM analysis of targeted sections, selected on the basis of the segmented tomograms. These in-situ and ex-situ characterization techniques were applied to study localized corrosion in a very early stage, on reinforced concrete cores retrieved from a concrete bridge. A number of interesting observations were made. First, the acquired images revealed the formation of several corrosion sites close to each other. Second, the morphology of the corrosion pits was relatively shallow. Finally, only about half of the total 31 corrosion initiation spots were in close proximity to interfacial macroscopic air voids, and above 90 percent of the more than 160 interfacial macroscopic air voids were free from corrosion. The findings have implications for the mechanistic understanding of corrosion of steel in concrete and suggest that multimodal in-situ imaging is a valuable technique for further related studies.

The transformation of 2-line ferrihydrite to goethite from supersaturated solutions at alkaline pH >= 13.0 was studied using a combination of benchtop and advanced synchrotron techniques such as X-ray diffraction, thermogravimetric analysis and X-ray absorption spectroscopy. In comparison to the transformation rates at acidic to mildly alkaline environments, the half-life,t_1/2, of 2-line ferrihydrite reduces from several months at pH = 2.0, and approximately 15 days at pH = 10.0, to just under 5 hours at pH = 14.0. Calculated first order rate constants of transformation, k, increase exponentially with respect to the pH and follow the progression log_10 k = log_10 k_0 + a*pH^E3. Simultaneous monitoring of the aqueous Fe(III) concentration via inductively coupled plasma optical emission spectroscopy demonstrates that (i) goethite likely precipitates from solution and (ii) its formation is rate-limited by the comparatively slow re-dissolution of 2-line ferrihydrite. The analysis presented can be used to estimate the transformation rate of naturally occurring 2-line ferrihydrite in aqueous electrolytes characteristic to mine and radioactive waste tailings as well as the formation of corrosion products in cementitious pore solutions.