Construction and Building Materials 255 (2020) 119377

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Construction and Building Materials

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Investigation on the electrochemical and mechanical performance of

CFRP and steel-fiber composite bar used for impressed current cathodic
protection anode
Yingwu Zhou a, Xubin Zheng a, Feng Xing a, Lili Sui a, Yaowei Zheng a, Xiaoxu Huang a,⇑
a
Guangdong Provincial Key Laboratory of Durability for Marine Civil Engineering, Shenzhen University, Shenzhen 518060, China

h i g h l i g h t s g r a p h i c a l a b s t r a c t

A new ICCP system was proposed

with CFRP bar or SFCB as the anode
material.

The electrochemical and mechanical
performances of CFRP bar and SFCB
was investigated.

CFRP bar and SFCB possess excellent
electrical conductivity and low
electrical resistance.

The mechanical properties of CFRP
bar and SFCB deteriorate after
polarization.

Dual-function of CFRP bar and SFCB
can be achieved in ICCP syetem.

a r t i c l e i n f o a b s t r a c t

Article history: Impressed current cathodic protection (ICCP) has been proved to be an effective method to inhibite steel
Received 23 September 2019 corrosion. Combined with ICCP technique, a new system has been proposed in this paper with carbon fiber
Received in revised form 11 March 2020 reinforced polymer (CFRP) as dual-functional material: auxiliary anode and partial reinforcement simulta-
Accepted 27 April 2020
neously. The electrochemical and mechanical performances of CFRP in the new ICCP system were investi-
gated experimentally with two kinds of reinforcement bar: CFRP bar and steel-fiber composite bar (SFCB).
First, the accelerated anodic polarization test and electrochemical impedance spectroscopy (EIS) measure-
Keywords:
ment were carried out for CFRP bar and SFCB to verify the electrochemical performances. Then, the mechan-
ICCP
CFRP bar
ical performance and underlying degradation mechanism were identified for CFRP bar and SFCB based on
SFCB the uniaxial tensile test and scanning electron microscopy (SEM). Finally, the service life of CFRP bar and
Anodic polarization SFCB has been evaluated to confirm the fesibility of the proposed system in practical engineering.
Dual-function Results showed that CFRP bar and SFCB possess excellent electrical conductivity and low electrical resis-
tance as the anode in ICCP system. Compared with SFCB, CFRP bar is more promising as an anode material
with a stronger polarization resistance capability, an acceptable degradation of the mechanical property
and a longer service life. With a current density of 20 mA/m2, the service life was evaluated as 62 years
for CFRP bar while 7 years for SFCB. To improve the application of SFCB in ICCP system effectively, some
modifications are necessary, such as replacing the inner steel bar with stainless steel bar or adding a pro-
tective layer between the steel bar and fiber layer. Furthermore, the proposed system shows great potential
for marine RC structures and the comprehensive study of this system will be carried out in future work.
Ó 2020 Elsevier Ltd. All rights reserved.

⇑ Corresponding author.
E-mail address: xxhruby@[Link] (X. Huang).

[Link]
0950-0618/Ó 2020 Elsevier Ltd. All rights reserved.
2 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

1. Introduction considered as the anode material, and the performance in ICCP sys-
tem should be further investigated.
Steel corrosion is considered as the main factor for the insuffi- Therefore, the basic idea of this paper is to study the electro-
cient durability of RC structures in a high chloride environment chemical and mechanical properties of CFRP bar and SFCB as aux-
[1]. To inhibit steel corrosion for RC structures, various technolo- iliary anodes of cathodic protection and reinforcement materials of
gies have been developed, such as rust inhibitors, epoxy-coating structures, and finally to establish a new cathodic protection sys-
and cathodic protection [2]. Among them, impressed current tem: ICCP-CB (ICCP-CFRP bar) and ICCP-SFCB (ICCP-Steel-fiber
cathodic protection (ICCP) has been proved to be one of the most composite bar). First, the accelerated anodic polarization tests
economical and effective methods [3,4]. The basic layout of the and EIS measurements were carried out for CFRP bar and SFCB to
ICCP system is to connect the steel bar with the negative pole of verify the electrochemical performances in chloride environment.
direct current (DC) power supply and the auxiliary anode with Then, the uniaxial tensile tests and SEM were performed after
the positive pole. A cathodic polarization for the steel bar can be polarization, to explore the mechanical performance and underly-
induced with the applied current, i.e., enough electrons are trans- ing degradation mechanism for CFRP bar and SFCB as anode mate-
ferred to the surface of the steel bar, and the potential is forced rials in cathodic protection. Finally, the service life of CFRP bar and
to a more negative level. Thereby, corrosion is finally weakened SFCB has been evaluated to confirm the fesibility of the proposed
and avoided [5,6]. It is well-known that the successful application system in practical engineering. Combined with ICCP technique,
of ICCP in RC structures largely depends on the selection of appro- carbon fiber reinforcement as well as SFCB, this system shows
priate anode system [7,8]. Many anode systems have been investi- great potential for marine RC structures as the dual-function of
gated for ICCP, including metalized zinc [8], conductive organic CFRP material can be achieved and steel corrosion can be further
paints [9], activated titanium mesh [10], and coating-overlay inhibited simultaneously.
anodes [11,12]. However, these anode systems are either suffering
from durability problems or highly expensive, limiting the wide 2. Experimental investigation
applications of ICCP technique.
Featured with high strength, good corrosion resistance, excel- 2.1. Anode materials
lent conductivity as well as electrochemical properties [13,14],
CFRP is not only an excellent structural reinforcement material As shown in Fig. 2 (a) and (b), the CFRP bar used here, made by
but also an ideal anode for ICCP system [15], which has been Toray T700 carbon fiber with a volume fraction of approximately
widely studied in last decade. The first experimental attempt of 60%, was supplied by Jiangsu Nantong Intelligent Fiber Technology
CFRP anode in ICCP was performed by Lee-Orantes et al. [16] Company. Besides, the SFCB was produced by Jiangsu Sende New
using 50, 100, and 1000 mA/m2 protection current densities. Composite Materials Company with the HF30S-12K carbon fiber
The results revealed that the steel bar was protected without provided by Jiangsu Hengshen Company. To show better conduc-
obvious degradation of CFRP and the conductive resin. Lambert tive performance for CFRP, the resin layer on the surface of CFRP
et al. [14] proposed a new technology of structural reinforcement was removed by precision grinding technology in the factory
and electrochemical protection for RC members using CFRP. The before testing. The mechanical performances of the anode materi-
dual-function was conformed experimentally: besides the protec- als were listed in Table 1. The diameter of the SFCB is 10 mm with
tion of steel bar, the stiffness was improved. For pre-corroded RC the diameter of the inner steel bar as 6 mm and the thickness of
beams, Nguyen et al. [17] studied the dual functions of CFRP bar. outer carbon fiber as 2 mm.
It also showed that the bonding performance between CFRP bar
anode and concrete interface can be improved by geopolymer 2.2. Electrolyte solution
and epoxy resin. Zhu et al. [18,19] proposed the ICCP-SS (im-
pressed current cathodic protection-structural strengthening) sys- In order to simulate the chloride environment, seawater was
tem (see Fig. 1(a)) with externally bonded CFRP as a dual- used as the electrolyte solution. The seawater solution in this
function material, and the electrochemical properties, mechanical experiment was taken from the offshore of Fuyong Wharf in Shen-
properties, and service life of carbon fiber under cathodic protec- zhen. The ionic parameters of seawater were shown in Table 2 [28].
tion working conditions have been studied. Nevertheless, a large
number of inorganic adhesives is required in this system, affect- 2.3. Accelerated anodic polarization test
ing the durability of the interface and the effectiveness of ICCP
seriously. Zhou et al. [20,21] has proposed a new ICCP system 2.3.1. Testing apparatus
with embedded CFRP bar as structural reinforcement and auxil- Based on the ICCP system, the constant current anodic polariza-
lary anode material, as shown in Fig. 1 (b). The effectiveness of tion acceleration test apparatus was designed, as shown in Fig. 3.
this system has been verified in the aspect of bonding and struc- The test system consists of a power supply, a CFRP bar or SFCB
tural performances. anode connected to the positive terminal, and a 304 stainless steel
However, even though CFRP bar shows excellent application sheet cathode connected to the negative terminal. The anode (i.e.,
potential, shortcomings remain, including high cost, full linear CFRP bar or SFCB) was placed on the left side with the test region of
elasticity, and low elastic modulus [22–26]. Thus, it is difficult to 250 mm length and the insulated non-test region of 540 mm
utilize CFRP bar directly as the support material in large-scale con- length. The cathodic stainless steel sheet was placed on the right
crete structures. To overcome this issue, a new hybrid bar, steel- side with a distance of 50 mm to the anode. In this experiment,
fiber composite bar (SFCB), has been proposed with steel bar as the primary reaction at anode performs as Eq. (1) [28]. In the pres-
the inner core, CFRP material as the outer layer and resin as the ence of chloride, chlorine is produced by Eq. (2) [29]. Furthermore,
bonding material [26,27]. The CFRP material and steel bar are chlorine reacts with water to produce HClO and HCl as Eq. (3).
loaded together with complementary advantages, i.e., not only Based on the principle of electrochemistry, the primary cathodic
improves the post-yielding performance of steel bar but also reduction at stainless steel occurs as Eq. (4).
makes up for the lack of ductility of CFRP bar. The cost of SFCB is þ
much lower than that of CFRP bar. Compared with steel bar, the 2H2 O ! O2 þ 4H þ 4e ð1Þ
mechanical properties of SFCB can be significantly improved. Since -
the outer layer is covered with CFRP material, SFCB can be also 2Cl ! Cl2 þ 2e -
ð2Þ
 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377 3

Fig. 1. Layout model of CFRP anode material. (a) Externally bonded CFRP anode; (b) Internal embeded CFRP bar.

CFRP Steel bar CFRP

(a) (b)
Fig. 2. Anode materials. (a) CFRP bar; (b) SFCB.

Table 1
Mechanical performance.

Specimen Diameter (mm) Yield strain (%) Yield strength (MPa) Ultimate strain (%) Ultimate strength (MPa) EI (GPa) EII (GPa)
CFRP 12 – – – 788 125 –
SFCB 10 0.21 305.58 1.36 641.46 130.60 51.80

Note: EI = Elastic modulus; EII= Post-yielding elastic modulus.

4 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

Table 2
Ion parameters (unit: mg/L).

Na+ K+ Ca2+ Mg2+ F- Cl- Br- SO2-

4 CO2–
3

4 3 4 3
395.0 422.5 1.24  10 1.00  10 5.14 2.00  10 48.55 1.82  10 7.54

Table 3
Test scheme.

Specimen ID Sw (mm2) I (mA) i (mA/m2) Duration (days)

C-M0-a 7854 0 0 –
C-M10-a 7854 8 1080 7, 14, 21, 28
C-M10-b 7854 8 1080 7, 14, 21, 28
C-M10-c 7854 8 1080 7, 14, 21, 28
C-M20-a 7854 17 2160 7, 14, 21, 28
C-M20-b 7854 17 2160 7, 14, 21, 28
C-M20-c 7854 17 2160 7, 14, 21, 28
F-M0-a 9424 0 0 –
F-M10-a 9424 10 1080 7, 14, 21, 28
F-M10-b 9424 10 1080 7, 14, 21, 28
F-M20-a 9424 20 2160 7, 14, 21, 28
F-M20-b 9424 20 2160 7,14, 21, 28
F-M50-a 9424 51 5400 14, 28, 42
F-M50-b 9424 51 5400 14, 28, 42
F-M50-c 9424 51 5400 14, 28, 42
F-M100-a 9424 102 10,800 14, 28, 42
F-M100-b 9424 102 10,800 14, 28, 42
F-M100-c 9424 102 10,800 14, 28, 42

*Note: Sw = the contact area between CFRP bar, SFCB and seawater solution.
I = constant current input to specimen.
i = anode current density.

Fig. 3. Anodic polarization acceleration test (unit: mm). (a) Design diagram of test equipment; (b) Entity diagram of test equipment.

Cl2 þ H2 O ! HClO þ HCl ð3Þ region was properly ground by sandpaper to increase the conduc-
tivity of carbon fiber on the surface.
þ
2H þ 2e -
! H2 ð4Þ
2.3.3. Accelerated test arrangement
In this experiment, the polarization degree of the anode mainly
2.3.2. Preparation of specimens depends on the chloride environment and the amount of electric-
The details of the specimen were depicted in Fig. 4. The entire ity. According to the NACE Standard SP0290-2007 [30], the maxi-
surface of each specimen was protected except for the test region. mum anode current density should below 108 mA/m2 for the
The protected region was first wrapped by insulating tape evenly protection system. In order to study the polarization resistance
and tightly, then coated with epoxy resin and silica gel succes- for CFRP bar and SFCB in practical engineering, an accelerated test
sively. In addition, prior to the anodic polarization test, the test is required. Thus, the maximum anode current density defined in
 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377 5

Fig. 4. Specimens for anodic polarization (unit: mm). (a) Details of the specimens;
(b) Preparation of specimens.

the standard [30] was magnified by 10, 20, 50, and 100 times, Fig. 5. Electrochemical impedance spectroscopy (unit: mm).
respectively, i.e., the anode current density in the acceleration test
was 1080, 2160, 5400 and 10800 mA/m2, respectively. The output imen during the tensile test, a gel-injected anchorage is necessary.
constant current density was about 10, 20, 51, and 102 mA, respec- The geometrical details of specimens were shown in Fig. 6 with the
tively. Since SFCB contains an inner steel bar, which shows a seri- following three preparation steps, as described in Fig. 7.
ous deterioration with large current densities, the standard current
density was only magnified by 10 and 20 times for SFCB while 10 (1) The bottom of the aluminum tube was sealed by the insulat-
to 100 times for CFRP bars. As listed in Table 3, 18 specimens were ing tape to prevent the glue from flowing out, and wires
prepared and named in the form of ‘‘reinforcement type – M + mag- were used at the upper and lower ends to center the speci-
nification factor of the maximum anode current density–specimen men vertically.
number.” For example, C-M10-a denotes that the maximum anode (2) Carbon fiber was coated with epoxy resin evenly and
current density defined in the standard is magnified by 10 times wrapped on reinforcement. The redundant resin was
(i.e., the current density is 1080 mA/m2). C and F denote SFCB squeezed out by tightening the carbon fiber. When the glue
and CFRP bar respectively; a, b and c denote the number of three was poured into two-thirds of the tube, the steel wrapped
repeated specimens. During the test period, the feeding voltages with carbon fiber was put into the tube slowly.
were collected and monitored every two days. To ensure the stabil- (3) The specimen was solidified vertically in the outdoor
ity of the solution, the swaying of the test apparatus and removing environment.
the cover on the test apparatus were not permitted when testing.
2.5.2. Tensile test arrangement
2.4. Electrochemical impedance spectroscopy measurement The tensile test was carried out based on the Pseudo-dynamic
Machine (Servotest-100 ton), as shown in Fig. 8. It is necessary to
The electrochemical impedance spectroscopy (EIS) was mea- raise the girder first, clamp one end and then descend the girder till
sured by the three-electrode system in this experiment [31,32]. the bottom of the reinforcement contacts with the fixture platform,
As shown in Fig. 5, the CFRP bar or SFCB was served as the working and clamp the fixture again. Otherwise, the reinforcement will be
electrode, the 304 stainless steel sheet was served as the counter compressed in advance or crushed when removed. The displace-
electrode, and a platinum electrode was served as the reference ment control method was adopted herein with the loading speed
electrode. Before the EIS test, the CFRP bar and SFCB were depolar- as 0.03 mm/s. The test was terminated once the displacement
ized for 4 hours to reach a stable state. For specimens with 10 increases and the load decreases.
times and 20 times magnification (i.e., F-M10, F-M20, C-M10 and
C-M20), the EIS test was performed on 7, 14, 21 and 28 days con- 2.6. Scanning electron microscopy test
tinuously. For specimens with 50 times and 100 times magnifica-
tion (i.e., F-M50 and F-M100), the EIS test was performed on 14, To observe the micromorphological variation for CFRP bar and
28 and 42 days continuously. All the above EIS tests were per- SFCB after the tensile test, the scanning electron microscopy
formed by PARSTAT 4000 + electrochemical impedance spectrom- (SEM) test was performed. The numbered specimens with cutted
eter with the frequency ranged from 100 kHz to 10 MHz [33]. section and surface were placed in the aluminium box and dried
for 24 hours by a vacuum dryer with a temperature of 60 °C. Then,
2.5. Uniaxial tensile test the specimens were taken out for SEM scanning test. The changes

2.5.1. Preparation of specimens

Following the anodic polarization test, uniaxial tensile tests of Aluminum tube Test region Aluminum tube
the samples were performed to obtain the degradation of mechan-
ical properties for CFRP bar and SFCB. Characterized by high tensile
strength and low compressive (shear) strength, the mechanical
property of CFRP bar and SFCB is anisotropic, which is different
from steel bar. In order to avoid damage to both ends of the spec- Fig. 6. Geometrical details (unit: mm).
6 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

Fig. 7. Setup for tensile test. (a) Aluminum tube; (b) Carbon fibre; (c) Unwrapping process; (d) Completed specimen.

of the micro-morphology in the fracture surface for CFRP bar and

SFCB with different current densities and polarization durations
were summarized. Moreover, the electrochemical and mechanical
properties of CFRP bar and SFCB were discussed.

3. Result and discussion

3.1. Experimental phenomena

After the start of the anodic polarization, bubbles appeared

around the stainless steel sheet in the test devices with 50 and
100 times current density amplification, and this phenomenon
was more remarkable for the latter case. The bubbles should be
Specimen hydrogen generated by the cathodic reduction reaction (i.e., Eq.
(4)). For SFCB, lots of floating yellowish-brown bubbles appeared
in the interface between SFCB surface and the solution after a per-
iod of anodic polarization, and the solution was changed from
transparent to dark brown. These bubbles should be oxygen and
chlorine generated by Eqs. (1) and (2). For CFRP bar, some floating
white bubbles have appeared in the surface contacted with solu-
tion, and the colour of the solution did not change significantly.
C-M series specimens were taken out after 28 days’ polariza-
tion, as shown in Fig. 9 (a). Compared with the reference group
(i.e., C-M0), the morphology of C-M10 has not changed obviously,
the surface of the carbon fiber has not deteriorated significantly,
Fig. 8. Tensile test arrangement. and the diameter of steel bar has not varied distinctly. However,
 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377 7

Fig. 10. Feeding voltage evolution. (a) C-M series; (b) F-M series.

Fig. 9. Apparent changes of anodic polarized specimens. (a) Anodic polarization for
28 days of C-M series; (b) Anodic polarization for 28 days of F-M series.
3.3. Analysis of EIS

parts of carbon fiber were adhered by some yellowish-brown sub- The analysis of EIS for CFRP bar and SFCB anodes was performed
stances, and the colour of carbon fiber nearby became dark. It was in this section. Based on the Versa Studio software, the real part

0
preliminarily considered that some resin on the SFCB surface was Z and imaginary part (Z) of impedance, as well as the scanning
not enough compact that the solution entered the steel bar and frequency can be obtained. Then, the impedance modulus (|Z|)
oxidized with the inner core subsequently, leading to the corrosion and the phase angle (/) of the impedance vector in the circuit
products. For C-M20, the state of carbon fiber on the surface was can be calculated as follows:
basically the same as that of C-M10, but the colour was darker than
that of C-M10. jZ j2 ¼ Z 02 þ Z 002 ð5Þ
F-M series specimens were taken out after 28 days’ polarization,
as shown in Fig. 9 (b). It can be visually observed that a sequence of
00  
arctan zz0  180
variations had been occurred for the CFRP bar, including soft car- /¼ ð6Þ
bon fiber on surface, increased diameter, and dark-yellow surface. p
The surface texture of F-M10 bar remained unchanged with Let the horizontal ordinate denote the frequency variation, the
slightly yellowish carbon fiber. For F-M20 bar, the surface mor- left and right longitudinal coordinate as the impedance modulus
phology has changed obviously compared with its original state, (|Z|) and phase angle (/), respectively. The bode plots were pre-
and the carbon fiber completely turned to yellow–brown with sented in Figs. 11-16, in which the black lines denoted the non-
slightly crisp. Compared with F-M20 bar, F-M50 bar was softer, anodic polarized specimens while the colour lines represented
and the surface morphology of carbon fiber can be observed. the polarized specimens. Two ordinates are depicted and distin-
Among F-M series specimens, F-M100 bar suffered to the most guished by the black arrow: the left and right arrows mean that
serious deterioration with the largest diameter, the blackened sur- the curve refers to the ordinate of impedance modulus and phase
face of carbon fiber, the invisible resin, and broken carbon fiber. angle, respectively. For a better understanding, the curves in the
dashed box represent the variation of the phase angle. The legend
3.2. Feeding voltage was labeled in the form of ‘‘reinforcement type – M + magnification
factor of the maximum anode current density – anodic polarization
During the anodic polarization period, the feeding voltage of the duration.” For example, C-M10-14 is the SFCB specimen with 10
specimens was observed every two days. Fig. 10 showed the vari- times of the maximum current density after 14 days’ anodic polar-
ation of the feeding voltage. The feeding voltage fluctuated in the ization. The phase angles of impedance vectors for all specimens
range of 2.8 V to 3.8 V for C-M series specimens while 2.2 V to were less than 90°, indicating that the interface of CFRP bar and
3.6 V for F-M series specimens. The variation trend of feeding volt- SFCB was an ideal capacitance.
age was relatively stable, which did not cause a great influence on Figs. 11 and 12 have shown the bode plots for SFCB with 10
the power supply [34]. Thus, it can be demonstrated that CFRP bar times and 20 times current density amplification, respectively. It
and SFCB, as an auxiliary anode material, possess stable electrical can be observed that the impedance of the ICCP system decreased
conductivity and relatively low output resistance [18,35]. gradually as the polarization duration increased while the phase
8 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

Fig. 11. Bode plot of the C-M10 specimens. (a) Bode plot; (b) Local bode plot.
Fig. 12. Bode plot of the C-M20 specimens. (a) Bode plot; (b) Local bode plot.

angle decreased with increasing current density. In the low-

frequency domain for C-M10 series, the impedance modulus of decreased to 18 Xcm2 after 7 days’ polarization. Moreover, after
SFCB decreased from 5000 Xcm2 to 140 Xcm2 after 7 days’ polar- 14 days’ polarization, the impedance modulus of F-M50 series
ization, indicating that the electrochemical performance of SFCB and F-M100 series also decreased to about 10 Xcm2. The impe-
had changed dramatically. After 14 days’ polarization, the impe- dance modulus in the low-frequency band tended to be stable
dance modulus decreased to 70 Xcm2 in the low-frequency and basically did not change.
domain and remained unchanged after 21 days’ polarization with Based on the above EIS results, it can be inferred that the elec-
a value approximate to 20 Xcm2. In the low-frequency domain trochemical properties of carbon fiber have changed significantly
for C-M20 series, the impedance modulus of SFCB sharply dropped after polarization. It is preliminarily analyzed that the properties
from 5000 Xcm2 to 90 Xcm2 after 7 days’ polarization, which is of carbon fiber degraded under the action of corrosive medium
close to the one for C-M10 series after 14 days’ polarization. The and polarization, due to the corrosion damage of resin matrix, car-
impedance modulus for C-M20 remained unchanged after 14 days’ bon fiber and interface. The deterioration can be explained in the
polarization. aspect of microstructure, electrolyte and electrochemical reaction.
Figs. 13-16 have depicted the bode plots for F-M series speci- It is reported that the arrangement of layers is irregular and disor-
mens with the current density magnified by 10, 20, 50, and 100 dered for the microstructure of carbon fiber, and many channels
times respectively. The impedance modulus of the unpolarized F- exist in CFRP. Thereby, the gas generated by the electrochemical
M series specimen (i.e., F-M0) in the low-frequency domain was reaction in the hole will cause mechanical and chemical damage
significantly smaller than that of SFCB. The impedance moduli of to the anode material, leading to the softness and expansion of
F-M0 were 750 Xcm2 and 45 Xcm2 in the low-frequency and the surface. In the constant current anodic polarization accelerated
high-frequency domain, respectively, indicating that the CFRP bar test, the CFRP material was mainly used for the anodic oxidation
had better conductivity than SFCB. The impedance modulus of F- reaction and electron exchange.
M10 series decreased to 35 Xcm2 in the low-frequency domain In general, the electrochemical reaction and performance of the
within 7 days’ polarization and tended to be stable after that, indi- anode are affected by the ions in electrolyte and the current den-
cating that the electrochemical performance of CFRP bar first chan- sity of the whole system. When the chloride content was relatively
ged dramatically within 7 days’ polarization. It can also be seen low or the current density was high enough, the mass transfer pro-
that the impedance modulus of the F-M20 series specimens cess of the solution ion was hindered. Once the chloride around the
 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377 9

Fig. 13. Bode plot of the F-M10 specimens. (a) Bode plot; (b) Local bode plot. Fig. 14. Bode plot of the F-M20 specimens. (a) Bode plot; (b) Local bode plot.

anode was consumed, then the oxygen evolution became the main Load-displacement curves of C-M series specimens were shown
anodic reaction. Various electrochemical reactions on the surface in Fig. 17 (a). For C-M series specimens, the whole test process was
of the anode lead to an increase in hydrogen concentration. Since divided into two stages. At the initial loading stage, the steel bar
the diffusion of the hydrogen ion was blocked, accumulation had not yet yielded with the load shared by the inner steel bar
occurred around the anode and the acidity nearby increased and the outer CFRP layer. As the load increased, the steel bar
accordingly, making the anode in a very harsh environment. yielded, and the additional load was all undertaken by the CFRP
Furthermore, the consumption rate of CFRP is closely related to layer. Then the fiber filament in SFCB gradually broke with the
the electrochemical reaction on the anode surface. When the chlo- decreasing of the tensile capacity for specimens. Finally, the tensile
rine evolution is the main reaction, the consumption rate varies from test was terminated once the bearing capacity reached its ultimate
0.14 kg/Aa to 0.23 kg/Aa. If the main reaction is oxygen evolution, the value, and the load decreased vertically. Two failure modes were
consumption rate can reach to 0.9 kg/Aa, since the carbon in graphite observed: fiber fracture and resin fracture. Furthermore, it can be
is oxidized to carbon dioxide in this case. Therefore, for the deterio- seen that when the current density was amplified by 10 times
ration of polymer materials containing carbon elements, the oxygen (i.e., C-M10), there was no significant impact on the overall
evolution reaction on the surface of the anode is more serious than mechanical properties of steel bar; while the carbon fiber rupture
the chlorine evolution reaction. In this test, the deterioration of car- in advance shortly after the steel bar yielded when the current
bon fiber was mainly contributed to the coupling of chemical corro- density was amplified by 20 times.
sion and physical corrosion. The chloride ion corrosive mediums (2) F-M Series
entered into the carbon fiber through adsorption and diffusion, Load-displacement curves of F-M series specimens were plotted
resulting in the change of the properties of carbon fiber, the swelling in Fig. 17 (b). Resin fracture occurred for all reinforcements. Differ-
of the resin, the transverse tensile stress on the interface and the ent from steel bar in yielding region and SFCB with quadratic stiff-
decrease of the interfacial bonding force. ness, the stress–strain curve of CFRP bar varied in a straight line till
fracture. When carbon fiber continued to withstand tension, the
3.4. Analysis of tensile test displacement increased as well as the load. The bearing capacity
reached its ultimate value and decreased vertically, indicating
3.4.1. Failure process and mode the termination of the tensile test. It can be observed that the bear-
(1) C-M Series ing capacity decreased as the current density increased.
10 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

Fig. 16. Bode plot of the F-M100 specimens. (a) Bode plot; (b) Local bode plot.
Fig. 15. Bode plot of the F-M50 specimens. (a) Bode plot; (b) Local bode plot.

3.4.2. Analysis of test results

The results of the uniaxial tensile test for all specimens were that, when the current density was small, there was a strong inter-
listed in Table 4 in detail. facial bond between carbon fiber and epoxy resin, and the surface
(1) C-M Series was smooth. With the current density increased, the volume of
After the polarization for 28 days, compared with C-M0, the resin decreased and the carbon fiber loosened. It can be explained
ultimate strength decreased by 3.7% on average for C-M10 while as follows. Under the action of polarization, the corrosive medium
44.2% for C-M20. The ultimate strength for C-M series was com- reacted with the resin matrix chemically to generate new com-
pared in Table 4. It can be indicated that SFCB suffered to a serious pounds, leading to the variation of properties for the resin matrix
deterioration after polarization with large current density. The as well as the occurance of chemical and electrochemical corro-
deterioration was further confirmed by the microscopic analysis sions [36,37].
in Section 3.5. Fig. 19 was the micro-morphology of CFRP bar after anodic
(2) F-M Series polarization with different current densities. It can be found that
For F-M series specimens, the ultimate strength of specimens the micro-morphology variation tendency of CFRP was similar to
with a current density less than 100 times magnification hardly that of SFCB specimens, further verifying the effect of current
changed after 28 days’ polarization. The ultimate strength density on the deterioration of carbon fiber. As the current den-
decreased by 5% on average for F-M10, and 4.77% for F-M20. After sity increased, some small cracks have appeared between the car-
42 days’ polarization, the ultimate strength decreased by 7.15% on bon fiber and epoxy resin, and even gradually evolved into large
average for F-M50, and 13.85% for F-M100. The details can be holes. The overall micro-morphology was also becoming rougher,
found in Table 4. In the aspect of the ultimate strength after polar- especially for F-M100. Based on the variation of micro-
ization, it can be inferred that CFRP bar showed a better mechani- morphology, it can be further concluded that with the increase
cal performance with slight deterioration compared with SFCB. of current density, the corrosive medium inevitably caused the
corrosion reaction of the resin matrix, resulting in the loss of
3.5. Microscopic analysis integrity between carbon fiber. Simultaneously, the resin between
carbon fiber was deteriorated, combined with the occurrence of
Fig. 18 depicted the micro-morphology of SFCB after anodic chemical and electrochemical corrosions, leading to the deteriora-
polarization with different current densities. It can be observed tion of reinforcement.
 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377 11

3.6. Feasibility of practical engineering application

3.6.1. Strength prediction

To enhance the possibility for ICCP-CB system and ICCP-SFCB
system in practical engineering, the degradation laws of CFRP bar
anode and SFCB anode were derived in this section based on the
results of anodic polarization and tensile test. Furthermore, the
corresponding prediction model of the ultimate strength can be
obtained, providing some suggestions for practical engineering if
the deterioration law of CFRP and SFCB for the whole stage is con-
sistent. Let the charge density and ultimate tensile strength as the
input and output variable, respectively, the experimental ultimate
strength was fitted, as expressed in Eqs. (7)-(8).

f SFCBu ¼ ð1  4:01q3:35 Þf SFCBuRF ð7Þ

f FRPu ¼ ð0:9541  0:0295qÞf FRPuRF ð8Þ

in which q means the charge density; fFRP-u-RF and fFRP-u denote
the tensile strengths of CFRP bar before and after anodic polariza-
tion, respectively; fSFCB-u-RF and fSFCB-u refer to the tensile strengths
of SFCB before and after anodic polarization, respectively.
The experimental values and predicted values of the ultimate
strength for C-M and F-M series were compared in Fig. 20 (a)
and (b), respectively. It can be observed that: 1) the experimental
values showed a good agreement with the predicted ones both
for SFCB and CFRP bar, hence Eqs. (7) - (8) can be used to predict
the ultimate tensile strength of CFRP bar and SFCB after polariza-
tion in high chloride environment, providing recommendations
for practical engineering; 2) there exists a distinguished difference
for the ultimate strength between SFCB and CFRP. For CFRP, the
strength deterioration can be accepted; however, for SFCB, the
strength decreased dramatically when the charge density was
0.52  107C/m2. The carbon fiber in the outer layer of SFCB and
the resin between the carbon fiber suffered to serious deteriora-
tions in the case of large current densities. The corrosive medium
entered into the inner part of SFCB and contacted with the steel
bar directly, leading to the steel corrosion. Therefore, it is necessary
to consider the current density, the area ratio of internal steel bar
to external fiber and the bonding layer between them when
Fig. 17. Load-deflection curves. (a) C-M series; (b) F-M series.
applied SFCB in ICCP system.

Table 4
Tensile test results of all specimens.

Specimen ID Failure modes Yield strength (MPa) Ultimate strength (MPa) Strength loss (%)
C-M0-a Fiber rupture 305.58 641.46 –
C-M10-a Fiber rupture 305.58 614.08 4.27
C-M10-b Fiber rupture 286.48 621.47 3.12
C-M10-c Test failed – – –
C-M20-a Fiber rupture 271.20 412.40 35.71
C-M20-b Fiber rupture 269.93 340.08 46.98
C-M20-c Fiber rupture 235.55 321.36 49.90
F-M0-a Fiber rupture – 833.23 –
F-M10-a Resin rupture – 771.99 5.00
F-M10-b Test failed – – –
F-M20-a Resin rupture – 764.30 5.98
F-M20-b Resin rupture – 784.11 3.55
F-M50-a Resin rupture – 755.72 7.04
F-M50-b Resin rupture – 774.56 4.72
F-M50-c Resin rupture – 734.15 9.69
F-M100-a Resin rupture – 688.97 15.24
F-M100-b Resin rupture – 708.86 12.80
F-M100-c Resin rupture – 703.02 13.52

* Note: In the test, due to equipment failure or improper operation of the test, the sign‘‘–” in the table indicates that no data or invalid data had been collected.
12 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

Fig. 18. SEM images of C-M series (1: 200). (a) C-M10; (b) C-M20.

Fig. 19. SEM images of F-M series (1: 200). (a) F-M10; (b) F-M20; (c) F-M50; (d) F-M100.

3.6.2. Service life assessment and anode is balanced; thus the total charge quantity between
The service life of the new cathodic protection system can be cathode and anode is equal [38], i.e., the total electric quantity
evaluated based on the proposed strength prediction model. Qanode passing through the surface of the anode bar is equal to
According to the NACE standard TM0294-2007 [38], the lifetime the total electric quantity Qcathodic passing through cathode bar,
of the ICCP system can be determined by the amount of electric- as shown in Eq. (9).
ity transferred between anode and electrolyte interface. In the
Q anode ¼ Q cathodic ð9Þ
process of cathodic protection, the reaction between cathode
 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377 13

Fig. 21. New type cathodic protection system.

section areas, respectively; na and nc mean the numbers of anode

reinforcement and steel bar, respectively; and l represents the
length of the component.
To assess the service life for the proposed new ICCP system
quantitatively, an RC beam subjected to a hypochlorite environ-
ment was considered, as shown in Fig. 21 [18]. The beam was fea-
tured with a width of b and a height of h0. Three CFRP bars or SFCBs
were arranged at the corner of the concrete beam, and three steel
bars were configured at the top row. A new type of ICCP system
was formed by connecting the steel bars (i.e., the cathode) to the
negative pole of power supply and the CFRP bars or SFCBs (i.e.,
the anode) to the positive pole. Assuming that the anode density
was given, the service life of the new ICCP system can be evaluated
according to Eq. (14). For this beam, the total electricity passed
through CFRP bar and SFCB can be calculated based on Eq. (10)
and Table 3. In this paper, the service life of a CFRP bar is defined
as the time with the ultimate strength of 20%-25% loss. Similarly,
Fig. 20. Fitting of the Ultimate Strength. (a) C-M series; (b) F-M series.
the service life of the carbon fiber coating outside SFCB will be
reached when corresponding percentage of the ultimate strength
with is lost.
Therefore, after 42 days’ polarization with a current density of
Q anode ¼ ia  t a  Sa ¼ qa  Sa ð10Þ 10800 mA/m2, the total electric density of CFRP bar anode is
3.92  107C/m2, and the ultimate strength of CFRP bar remains
Q cathodic ¼ ic  t life  Sc ð11Þ 88%. Assume that the surface area of cathode reinforcement is
the same as that of anode reinforcement, and the current density
in which ia and ic denote the current densities through each
equals to 20 mA/m2 [20], then CFRP bar can still service normally
anode bar and each steel bar with the unit of mA/m2, respectively;
for 62 years with an acceptable deterioration. However, SFCB can
Sa and Sc are the surface areas of the structure where the cathodic
only service normally for 7 years with 80% ultimate strength
and anodic reactions occur, respectively; ta is the test time in units
remains under the same conditions for CFRP bar. As mentioned
of second; tlife is the service life of the new cathodic protection sys-
in Sections 3.5 and 3.6.1, the huge difference in service life can
tem controlled by the total anode power, which can be derived as
be attributed to the inner steel corrosion in SFCB. Therefore, to pre-
follows:
vent the inner steel corrosion and apply SFCB more effectively in
sffiffiffiffiffiffiffiffiffiffiffiffiffi
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ICCP system, the steel bar can be replaced by a stainless steel bar
A qa bh0
qa ¼ a ! ra ¼ ! Sa ¼ 2pr a l ¼ l 4pna qa bh0 ð12Þ or a protective layer can be added between the steel and fiber
bh0 na p
layer.
sffiffiffiffiffiffiffiffiffiffiffiffiffi
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
A qc bh0
qc ¼ c ! rc ¼ ! Sc ¼ 2pr c l ¼ l 4pna qc bh0 ð13Þ 4. Conclusions
bh0 nc p
Combined with ICCP technique, a new system has been pro-
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Q q  Sa qa l  4pna qa bh0 posed in this paper with carbon fiber reinforced polymer (CFRP)
t life ¼ anode ¼ a ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð14Þ
ic  Sc ic  Sc ic l  4pnc qc bh0 bar or steel-fiber composite bar (SFCB) as dual-function material:
auxiliary anode and partial reinforcement simultaneously. The
where qa and qc represent the reinforcement ratios of anode rein- electrochemical and mechanical performances of CFRP bar and
forcement and steel bar with Aa and Ac denote the corresponding SFCB in the new ICCP system were investigated experimentally,
14 Y. Zhou et al. / Construction and Building Materials 255 (2020) 119377

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