Corrosion of galvanized steel in alkaline solution associated with sulfate and chloride ions

Abstract

Corrosion mitigation strategies for structural steel bridge elements including post tensioned steel components include the use of galvanized steel. The zinc alloy layers and subsequent precipitation of a dense surface oxide in alkaline environments provide beneficial barrier protection to mitigate corrosion. However, severe corrosion of galvanized steel components in contact with sulfate-rich deficient cementitious grout was documented to occur in less than 8 years of bridge service. Electrochemical testing and material characterization showed that the presence of sulfates in alkaline solutions allow for prolonged zinc activity and hindered passivation by the incomplete surface coverage and the precipitation of large sized calcium hydroxy zincate. OCP, LPR, and electrochemical noise (EN) testing showed greater corrosion activity of galvanized steel in chloride and sulfate solutions. EN identified local corrosion activity of the zinc associated to the porous nature of the surface oxide layer.