Investigating non-uniform corrosion induced concrete cover cracking with a fracture-contact coupled computational method

Corrosion of steel rebar causes cracks in concrete, significantly impacting the durability of reinforced buildings. While various computational methods aim to simulate this process, only a few successfully handle both internal corrosion pressure and surface crack width evolution. To address this limitation, the study introduces an innovative mesoscale fracture-contact coupled computational method that seamlessly integrates with ABAQUS. Unlike current methods, it creatively utilizes interface elements to model stress transfer and crack propagation under tension in concrete. Additionally, it includes an additional contact model to represent the material's response to compression and shear forces. These innovations allow for accurate simulation of plain concrete mechanical properties under both tension and compression, effectively illustrating the development and failure patterns of cracks in the reinforced concrete cover. After calibrating and validating the method, the study thoroughly analyzed the process of concrete cover cracking, considering factors such as water to cement ratio, spatial location, geometry and size of coarse aggregate, rebar diameter and cover thickness. The modeling results reveal the following findings: (i) Changes in the shape and size of coarse aggregates have minimal effects on internal pressure and crack width. (ii) Higher concrete strength correlates with increased pressure on the outer surface of the rebar in an almost linear fashion, but it has little impact on surface crack width. (iii) Increasing the bar diameter decreases rust pressure but results in more cracks and wider surface cracks. (iv) Augmenting the cover thickness intensifies rust-induced pressure while simultaneously widening surface cracks.