Non-uniform distribution model of rust layer around steel bar circumference and its effect on corrosion-induced concrete cracking

This paper presents a critical review of non-uniform distribution models of rust layer around a reinforcing bar's circumference and a numerical investigation into the effect of non-uniform distribution of rust on (a) crack patterns and (b) development of concrete surface crack width. Different shapes of rust layer simulated by mathematical models were established based on statistical distribution functions which were compared with the transport-electrochemical model and published testing results. In addition, an advanced 2D finite element model was implemented to simulate crack propagation in concrete caused by rebar corrosion. It is found that non-uniform rust distribution shape around the rebar not only affected concrete surface crack width evolution, but also crack length and crack pattern. Transport-electrochemical model and Gaussian distribution-based model could reasonably simulate rust distribution and associated corrosion-induced cracks. In addition, the authors proposed a simplified semi-empirical model that incorporated an analytical chloride transport model and a Gaussian model to simulate time-dependent advancement of non-uniform rust layer. Furthermore, a parametric study of the effect of elastic stiffness of the rust layer on crack patterns and surface crack width development was also performed.