Enhancing Strength and Corrosion Resistance of Steel-Reinforced Concrete: Performance Evaluation of ICRETE Mineral Additive in Sustainable Concrete Mixes with PFA and GGBS

Abstract

This study investigates the impact of an innovative mineral additive, ICRETE, on steel-reinforced concrete’s compressive strength and corrosion resistance. Nineteen concrete mixes were designed incorporating recycled industrial by-products, including Ground Granulated Blast Furnace Slag (GGBS) and Pulverized Fuel Ash (PFA), with varying dosages of ICRETE. Compressive strength was tested using cube specimens, cured, and assessed at 3, 7, and 28 days following IS 516-2018 standards. Corrosion behavior was evaluated in accordance with ASTM G109, employing macrocell potential monitoring and electrochemical methods, including Tafel extrapolation and linear polarization resistance. The results revealed that ICRETE-enhanced mixes achieved compressive strengths of 56.93 MPa at a water–cement ratio of 0.35 and 50.61 MPa at 0.38, surpassing the control mix’s 50.9 MPa at 0.33. Microstructural analysis via X-ray diffraction (XRD) and scanning electron microscopy (SEM) showed that ICRETE improved hydration, reduced porosity, and refined the microstructure, contributing to more excellent durability. Meanwhile, results demonstrated that the ICRETE additive reduced corrosion rates, displaying lower corrosion current densities and higher polarization resistance values where the corrosion rate dropped from 0.01 mmpy in control samples to 0.0081 mmpy with ICRETE. Environmental assessments indicated that ICRETE could significantly lower CO₂ emissions, reducing up to 46.50 kg CO2 per cubic meter of concrete. These findings highlight ICRETE’s potential to enhance strength and durability, supporting its use in sustainable, eco-friendly concrete applications.