Investigating Reinforcement Shadow Visibility on Formed Concrete Surfaces Using Visual Inspection and Colour Variation Analysis

The research presented in this article seeks to identify the possible causes of reinforcement shadows (RS) on the surface of concrete test specimen produced under laboratory conditions. Different hypotheses about RS were selected based on factory practices and simulated in the study. The test specimens were cast horizontally in contact with steel form-facing surfaces coated with a water-soluble release agent. In addition, two scenarios were analysed during specimen production: reinforcing mesh was fixed using plastic spacers or tie wire. The analysis of the reinforcement shadows was based on visual inspection, taking photos, surface moisture content measurements, and colour variation analysis using the Natural Colour System. It was concluded that RS, which are typically characterized by darker lines, can be defined by the percentage of black colour present in the shadowed area compared to the percentage of black colour in the surrounding area. This percentage can be quickly assessed on a factory scale using digital colour readers that provide timely information. The reduced concrete cover thickness from 35 mm to 10 mm revealed light horizontal dark lines on the exposed surface. It was hypothesised that the gap of less than 10 mm between the reinforcing bars and the steel form-facing plate, along with the sieving effect of the fresh concrete, can retard the cement paste hydration process, resulting in unhydrated ferrite phases that contribute to the dark colour of the unhydrated cement. The release agent sprayed on the steel form-facing surface straight through the reinforcing mesh created a RS effect of the reinforcement on the exposed concrete surface. The absence of a release agent under steel rebars decreased the wettability at the interface between the formwork and fresh concrete, resulting in dark lines during the curing process. It is important to avoid such cases when manufacturing precast reinforced concrete elements. Quantitatively assessing RS and proposing a standardized method for calculation and categorization could be a new research direction in the future.