Galvanic corrosion and cathodic protection of re-grouted, post-tensioned (PTd) concrete systems

Abstract

Grouted post-tensioned (PTd) concrete systems are widely used in long-span segmental bridges with a target service life of 100+ years. However, the usage of inadequate grout materials and grouting practices have resulted in the formation of unwanted air voids in the duct, which in turn led to premature corrosion (say, within about 20 years) of strands and failure of tendons. Also, the re-grouting/repairing of void regions have led to localized corrosion of strands at the interface between the dissimilar base-grout (usually carbonated) and repair-grout. This study aims (i) to quantify the galvanic corrosion at the void region in a PTd system re-grouted with a dissimilar grout and (ii) to develop cathodic protection system to protect PTd anchorage regions. Specimens simulating the re-grouted strand-grout-air (SGA) interface were prepared with prestressing steel wires and cementitious grout. The macro-cell current (galvanic current) between the prestressing steels embedded in carbonated base-grout and repair-grout indicated that galvanic corrosion can be possible at the SGA interface – reducing the long-term structural reliability of re-grouted PTd bridges. In addition, the feasibility of galvanic anode cathodic protection system to protect PTd anchorage regions was assessed. For this, a proof-of-concept study was conducted to validate that a thin layer of grout around the strand will be sufficient for a galvanic anode (connected to the end of the strand at outside the tendon anchorage) to protect the strand portions inside the duct/anchorage.