Bridging the Gap: Assessing Material Performance of Laboratory Specimens and Concrete Structures

Chloride ingress and carbonation pose a significant risk of steel rebar corrosion in concrete structures. Various models exist to simulate the initiation phase of rebar corrosion, addressing both carbonation and chloride ingress mechanisms separately. These models also consider the environmental loads and material resistances, typically determined through laboratory testing based on specific standards. However, recent findings show significant differences between material resistances obtained from standardized laboratory specimens and those extracted from real structures, with the latter exhibiting inferior performance on average. To address this issue, a comparative study was conducted between laboratory specimens and on-site test walls or slabs, all cast using the same concrete batch. This study encompassed five construction sites featuring different concrete compositions. While laboratory specimens adhered to European curing standards, the walls were subjected to formwork curing for a predetermined period (typically 7 days) to simulate practical conditions. In some instances, a portion of the test walls/slabs received only one day of surface curing to emulate inadequate curing conditions. Subsequent testing of compressive strength and resistance to chloride ingress revealed that field specimens exhibited lower material resistance compared to their laboratory counterparts. This trend was also observed in the modulus of elasticity and carbonation rate. Notably, shorter curing periods further compromised performance, particularly resistance to chloride ingress and carbonation. These findings highlight the importance of establishing acceptance criteria not only for concrete delivered to construction sites but also for ensuring the quality of the actual structure.