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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.

Currently, large infrastructures (bridges, highways, etc.) are designed for more than 100 years. To achieve long service life, coated rebars (mostly, cement polymer composite (CPC) coated rebars) are being used to enhance the corrosion resistance. However, inadequately coated rebars can lead to premature corrosion. This can also affect the bond between the rebar and the concrete. To assess the effect of CPC coating on bond strength, pull-out specimens of (150×150×100) mm with 12 mm diameter rebar with 100 mm embedded length were cast and tested. For this, three replica specimens with two types of reinforcement namely, i) Uncoated steel ii) CPC coated steel were cast. To induce corrosion, additional five specimens with CPC coated steel rebars were cast with premixed chloride and cured for 28 days. During the curing period, continuous monitoring of corrosion potential and rate was done and degree of corrosion was assessed. The effect of degree of corrosion on bond of steel-concrete-coating interface was quantified. The CPC coated rebars without corrosion exhibited 10% bond reduction. CPC coated rebars with corrosion exhibited 30-70% reduction in bond strength. Also, the corrosion is found to adversely influence the stiffness of the bond.

Fusion-bonded-epoxy (FBE)-coated steel rebars have been used in many concrete structures in anticipation of better corrosion resistance. However, due to premature corrosion observed, FBE-coated rebars are banned in many parts of the world. On the other hand, such rebars with damaged coating are still used widely in some other parts of the world. This paper discusses the thickness, continuity, flexibility, and chemical composition of coating. Also, the performance indicators such as electrical resistance, UV-resistance, moisture resistance, and chloride diffusion coefficient of coating, and the chloride threshold of FBE-coated rebars are discussed. Laboratory tests adopted techniques (EIS, LA-ICP-MS, and EDX) on samples of coating peeled-off from coated rebars and specimens of coated steel rebars embedded in cement mortar, indicate that more comprehensive and stringent specifications are required to promote the use of quality epoxy materials, FBE-coated steel rebars, and construction practices are recommended. [ABSTRACT FROM AUTHOR]