The confused world of sulfate attack on concrete

Abstract

External sulfate attack is not completely understood. Part I identifies the issues involved, pointing out disagreements, and distinguishes between the mere occurrence of chemical reactions of sulfates with hydrated cement paste and the damage or deterioration of concrete; only the latter are taken to represent sulfate attack. Furthermore, sulfate attack is defined as deleterious action involving sulfate ions; if the reaction is physical, then, it is physical sulfate attack that takes place. The discussion of the two forms of sulfate attack leads to a recommendation for distinct nomenclature. Sulfate attack on concrete structures in service is not widespread, and the amount of laboratory-based research seems to be disproportionately large. The mechanisms of attack by different sulfates—sodium, calcium, and magnesium—are discussed, including the issue of topochemical and through-solution reactions. The specific aspects of the action of magnesium sulfate are discussed, and the differences between laboratory conditions and field exposure are pointed out. Part II discusses the progress of sulfate attack and its manifestations. This is followed by a discussion of making sulfate-resisting concrete. One of the measures is to use Type V cement, and this topic is extensively discussed. Likewise, the influence of w/c on sulfate resistance is considered. The two parameters are not independent of one another. Moreover, the cation in the sulfate salt has a strong bearing on the efficiency of the Type V cement. Recent interpretations of the Bureau of Reclamation tests, both long term and accelerated, are evaluated, and it appears that they need reworking. Part III reviews the standards and guides for the classification of the severity of exposure of structures to sulfates and points out the lack of calibration of the various classes of exposure. A particular problem is the classification of soils because much depends on the extraction ratio of sulfate in the soil: there is a need for a standardized approach. Taking soil samples is discussed, with particular reference to interpreting highly variable contents of sulfates. The consequences of disturbed drainage of the soil adjacent to foundations and of excessive irrigation, coupled with the use of fertilizer, are described. Whether concrete has undergone sulfate attack can be established by determining the change in the compressive strength since the time of placing the concrete. The rejection of this method and the reliance on determining the tensile strength of concrete because of “layered damage” are erroneous. Scanning electron microscopy (SEM) should not be the primary, and certainly not the first, method of determining whether sulfate attack has occurred. Mathematical modeling will be of help in the future but, at present, cannot provide guidance on the sulfate resistance of concrete in structures. Part IV presents conclusions and an overview of the situation, with consideration of future improvements. Appendix A contains the classification of exposure to sulfate given by various codes and guides.