Electrochemical Assessment of Galvanized Steel Corrosion in Alkaline Sulfate Solution

Abstract

Corrosion of steel prestressing strand in bonded post-tensioned bridge tendons have been associated with elevated concentrations of sulfate ions in deficient grout that can develop due to grout segregation [1]. Previous research indicated that the early presence of elevated sulfate ion concentration in the deficient grout in contact with the embedded steel can impair steel passivity. Metastable pitting was observed for steel in saturated calcium hydroxide solutions with sulfate ion concentrations greater than 1,300 ppm and pitting was observed in solutions above 20,000 ppm [2-4]. In addition to steel strand corrosion, galvanized steel ducts in direct contact with the deficient grout with elevated sulfate ion concentrations were also observed to have severe localized corrosion [1]. Galvanized steel in alkaline solutions, such as in cement pore water, have been characterized to have greater resistance to chloride-induced corrosion with chloride threshold concentrations as much as 2.5 times greater than carbon steel [5]. Information relating to sulfate concentrations is less available. Electrochemical testing including the electrochemical noise (EN) technique was conducted to identify the role of early sulfate ion presence on corrosion of galvanized steel.EN provides a test method to assess the corrosion modality without the influence of an external excitation that can affect the electrode surface and electrolyte chemistry (such as metal oxidation and oxygen reduction) [6-7]. The testing aims to identify the corrosion mitigation characteristics of the galvanized steel such as zinc activity and protective barrier surface oxide layers in presence of sulfate ions as well as combined cases with chloride ion contamination below reported threshold concentrations for galvanized steel. In the testing here, steel specimen were exposed to alkaline solutions simulating pore solutions with pH 12.6 with varying sodium sulfate levels and sodium chloride. Supplemental electrochemical experiments included the steady-state condition (open circuit potential, linear polarization test, and electrochemical impedance spectroscopy). References K. Lau, and I. Lasa. "Corrosion of prestress and post-tension reinforced-concrete bridges." Corrosion of steel in concrete structures. Woodhead Publishing, 2016. 37-57. DOI: https://doi.org/10.1016/B978-1-78242-381-2.00003-1.S. Permeh, K. K . Krishna Vigneshwaran, K.Lau., and I.Lasa. “Corrosion of Post-Tensioned Tendons with Deficient Grout. Part 3: Segregated Grout with Elevated Sulfate and Vestigial Chloride Content.” Corrosion 75 (2019) pp.848-864.S. Permeh, K. Lau, M. Duncan, and R. Simmons. “Initiation of localized steel corrosion in alkaline sulfate solution.” Materials and Structures, 54 (2021), pp.1-17.S. Permeh, K. Lau, M. Duncan, and R. Simmons. “Identification of steel corrosion in alkaline sulfate solution by electrochemical noise.” Materials and Corrosion, 72(2021), pp.1456-1467.S. Yeomans. Galvanized steel reinforcement in concrete. Elsevier, 2004.S. Permeh, and K. Lau. "Electrochemical Behavior of Steel in Alkaline Sulfate Solutions with Low Level Chloride Concentrations." ECS Meeting s. No. 10. IOP Publishing, 2021.K. Lau, S. Permeh. “Assessment of durability and zinc activity of zinc-rich primer coatings by electrochemical noise technique.” Progress in Organic Coatings, 167(2022): 106840.