- Corrosion of steel reinforcement bars (rebars) placed in reinforced concrete is a process in which a film of rust is formed on the steel bar due to chemical or electrochemical reaction. There are various environmental parameters which individually or in combination lead to corrosion of rebars in reinforced concrete structures. When rebar corrodes, the resultant rust occupies a greater volume than the steel. This expansion creates tensile stresses in the concrete, which can eventually cause cracking in concrete.
- In view of above, it is important to study the process of corrosion in a rebar and effect of such corrosion on reinforced concrete. Depending on exposure of reinforced concrete structure to corrosive environment, rate of corrosion of rebar varies. Moreover, due to protective nature of concrete, it takes a reasonably long time for initiation and progress of corrosion of rebars even in the case of severe corrosive exposure conditions. Accordingly, in order to study the structural effects due to rebar corrosion, the corrosion process is accelerated.
- The impressed current method is one of the prominent methods to accelerate the corrosion process. In operation, a voltage is applied between rebar and cathode and anodic current is observed whereby mass loss and corrosion rate of rebar can be estimated.
Figure (1) The image shows multiple views of the developed interface circuit enclosed in a custom 3D-printed casing. The setup integrates a microcontroller, current sensing modules, jumper switches, temperature-humidity sensors, and a real-time clock, with terminal blocks for input/output connections. The LCD display on the top panel provides real-time monitoring of key parameters such as current, voltage, temperature, and humidity; (2) The rendered schematic shows the internal layout of the interface circuit enclosure, highlighting key components including the microcontroller, terminal blocks, current sensing module, jumper switch, real-time clock (RTC), temperature-humidity sensor, SD card module, and voltage regulation components; (3) The image shows a multi-chamber corrosion acceleration system for testing pull-out specimens. The setup includes a corrosion accelerating cum monitoring device (inset), display unit, voltage/current (V/I) regulator, and a 48V DC rectifier. Each chamber simulates corrosion conditions, while the interface circuit monitors parameters like current, voltage, and environmental factors in real-time.
Corrosion of steel reinforcement bars (rebars) in concrete is a chemical or electrochemical process that forms rust, which expands and causes internal stresses, leading to concrete cracking. The corrosion rate depends on environmental factors like chlorides, moisture, and oxygen, but due to concrete's protective nature, the process is usually slow. To study structural impacts efficiently, corrosion is often accelerated using methods like the impressed current technique, where a voltage induces anodic current to simulate rapid corrosion. Accurate assessment of corrosion levels requires real-time monitoring, typically achieved through a data acquisition system that controls and records key parameters throughout the test.
- Data Acquisition: This interface circuit provides a simple and cost-effective solution for acquiring data related to corrosion acceleration tests. It is versatile and can be integrated into any configuration of accelerated corrosion test apparatus.
- Process Control and Monitoring: The circuit enables acceleration, control, and monitoring of various parameters involved in the corrosion acceleration process. This enhances the effectiveness and reliability of the testing procedure.
- Configurable Interface: The interface circuit includes a jumper module that enables switching between two different configurations of the corrosion setup, making it universally adaptable.
- Integrated Sensing Modules: Equipped with current sensor, real-time clock, temperature and humidity sensors, and a voltage divider, the circuit enables comprehensive, real-time monitoring.
The developed prototype is an interface circuit integrated with an accelerated corrosion test apparatus to study corrosion in steel reinforcement bars embedded in concrete. It features a jumper module and current sensor module that enable flexible operation across different corrosion test configurations by allowing the current sensor to be positioned appropriately in the circuit. The system includes a real-time clock module to monitor test duration, temperature and humidity sensors to capture environmental conditions, and a voltage divider circuit to measure supply voltage. A microcontroller processes data from all sensors, displays real-time values on an LCD screen, and logs the information in onboard memory for analysis. All components are pre-fabricated and mounted on a compact printed circuit board (PCB), offering a simple, reliable, and cost-effective solution. The prototype has been validated on multiple rebar specimens, effectively tracking parameters such as corrosion rate, mass loss, and resistance under controlled conditions.
The developed system is a working prototype that has been successfully tested under laboratory conditions and validated for its intended performance. It integrates an embedded data acquisition interface with modular electronic components, including a regulated DC power supply, current sensing modules, a voltage divider circuit, temperature and humidity sensors, a real-time clock, and an Arduino-based microcontroller system.
The system supports both high-side and low-side current sensing configurations, enabling flexible testing of multiple rebar specimens simultaneously. It records all critical parameters—such as anodic current, voltage, ambient temperature, relative humidity, and time—at regular 5-minute intervals (can be customized), facilitating real-time monitoring and control of the corrosion acceleration process. The device enables accurate estimation of corrosion rates and theoretical mass loss using Faraday’s law.
The prototype has exhibited stable and repeatable operation across multiple tests and in environments simulating real-world corrosion scenarios. The hardware is implemented on a compact printed circuit board (PCB), making the system portable and easy to deploy. Having reached Technology Readiness Level (TRL) 6, the technology is now ready for pilot-scale deployment, industry adoption, technology licensing, and scale-up for broader application in infrastructure durability assessment, materials research, and corrosion testing laboratories.
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The interface circuit for accelerated corrosion testing plays a vital role in improving the durability and safety of concrete infrastructure. By enabling real-time monitoring of corrosion parameters, it allows researchers and engineers to better understand how and when steel reinforcement degrades under various environmental conditions. This insight supports the development of longer-lasting structures, reducing the risk of sudden failures in critical assets like bridges, buildings, and flyovers.
- Civil Engineering Research: For studying corrosion mechanisms and evaluating structural durability.
- Infrastructure Health Monitoring: In assessing and predicting the lifespan of concrete structures like bridges, tunnels, and buildings.
- Construction Materials Testing: To test and compare corrosion resistance of different rebar materials and coatings.
- Quality Control in Manufacturing: For validating corrosion performance of reinforcement bars during production.
- Academic Laboratories: As a teaching and demonstration tool for structural engineering and material science courses.
- Corrosion Consultancy Services: Used by consultants and testing agencies for forensic analysis of damaged or aging infrastructure.
Geography of IP
Type of IP
201921020474
436523