CORROSION DEVELOPMENT OF POST TENSIONED TENDONS WITH DEFICIENT GROUT

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1 CORROSION DEVELOPMENT OF POST TENSIONED TENDONS WITH DEFICIENT GROUT Kingsley Lau and Mario Paredes Florida Department of Transportation, State Materials Office 57 NE 39 th Ave. Gainesville, FL PTI Convention Nashville, Tennessee. May 7, 212 Durability of Post Tensioned Infrastructure

2 INTRODUCTION: Post Tensioned Strand Corrosion Several Documented Cases of Corrosion Related Failures of Post Tensioned (PT) Strand in FL. Corrosion identified in early 2 s attributed to grout void formation due to bleed water formation and chloride presence. Subsequent specifications in FL include low bleed grout requirements. Photo courtesy of Parsons Brinckerhoff However, corrosion problems persist. Investigation of recent PT corrosion and repair issues are on going. This presentation overviews current findings from field and laboratory explorations of deficient grout in tendons.

3 BACKGROUND: PT Bridge in Florida built in 22 PT segmental bridge with int. and ext. tendons. Among first FL bridges to use low bleed grouts. Ext. Tendons placed to reduce tensile stresses in web. Anchor caps at low elevation. Severe corrosion in multiple ext. tendons. Failure occurred after ~8 years service. Severe corrosion accompanied by wet plastic grout. Pier Pier Deviators Anchor Cap

4 SEGREGATED GROUT A Grout segregation characterized as: A. Wet plastic B. Sedimented Silica C. White chalky A View of tendon top C Corrosion attributed to wet plastic grout but not necessarily to void presence. Grout segregation created environment with dissimilar pore water chemistry and physical properties.

5 Segregated Grout Properties: Moisture Content Moisture Content /% Corrosion Failure/ Chalky Grout Bottom 2 2 Bottom Bottom Bottom Bottom Bottom 32 Tendon Section 32 Soft Black 35 Bottom Bottom Bottom Corrosion Failure/ Wet Plastic Grout Moisture Content /% East Anchor E Low 36B Eeviator 34B 34B Bot /Soft 33B 33B 33B Bot 33A Bot 32A Bot /Soft Tendon Section 33A 32A Bot 32B Bot 31B Bot 3A 28B Bot/Dev High moisture content associated with segregated grout. ~5% moisture in white chalky grout; ~7% moisture in wet plastic grout

6 Segregated Grout Properties: Pore Water ph Regions with severe corrosion 14 Pore Wtaer ph Bot 27 Bot A 33B So W. Anch. So So So So So So So U 41 9D CT Tendon Section Prepared by Ex situ Leaching Method Pore water of segregated grout typically retains high ph. No indication of processes to decrease ph such as carbonation. Regions with accumulation of corrosion products may contain localized low ph environments.

7 Segregated Grout Properties: Chloride Content Total Chloride /mgcl g 1 grout Moisture Content /% Free Chloride Concentration (ppm) Assuming threshold ratio [Cl ]/[OH ] =.3, and an upper measured free Cl concentration ~5 to 1 ppm, threshold pore water ph (< ) < observed ph values (typ. >12). Assuming 67% cement content in grout, upper range.3mg/g Cl would correspond to.5% cement which is <<C T. Low chloride content associated with segregated grout. Below conventional chloride corrosion threshold concentrations. Accumulated chloride content in moist grout may be due to ionic transport. However, total chloride test preparation methods may over sample size of segregated grout thus higher reported chloride concentrations.

8 Segregated Grout Properties: Grout Content Cumulative Fraction Others New Bottom XRF Counts Sulfur /1 3 s 1 + Gypsum Δ Ettringite None Mix Bottom A B1A A 1 3 A A Gypsum Apparent enhanced presence of sulfurous compounds in segregated grout. Gypsum and ettringite identified as sulfur bearing crystalline compounds. Ettringite filled voids visually predominant in segregated grout; however, identified in grout in vicinity of segregated grout as well A Ettringite 3 A Possible indicator of enhanced sulfate presence segregated grout free water. A Dev/Light Dev/Dark 32A Bot 32B /Soft 32B Bot 31B /Dark 31B /Dark 31B 31B Bot/Dark 31B Bot/Rust

9 Segregated Grout Properties: Pore Water Content 1 Concentration (ppm) Bot 27 Bot A 33B W. Anch SO4 2 Ca 2+ Cl CT Tendon Section Concentration (ppm) Bot 27 Bot A 33B W. Anch K+ Na CT Tendon Section Sulfate concentrations as high as 97 ppm measured in pore water. Apparent lower concentrations of Na +, K +, and OH and the higher Ca 2+ concentration in the segregated grout than elsewhere.

10 Corrosion at Low Elevation Anchor Caps Pier Pier Deviators Anchor Cap Corrosion and similar deficient grout characteristics observed at low elevations, too.

11 II III IV V I Concentration (ppm) 421L I 421L II 421L III 421L IV 421L V NEW Moisture Content % SO42 K+ Na+ Ca2+ Cl NO Total Chloride Content / mgcl mgdry 1 421L I 421L II 421L III 421L IV 421L V ph Estimated

12 CORROSION CONDITIONS IN SEGREGATED GROUT Cumulative Fraction Cumulative Fraction Inside.8 2 Inside.7 27 Inside.6 32 Inside Inside.3 34 Inside.2 35 Inside.1 47 Inside E /mv CSE E corr, active E η a I corr, active- macrocell I corr,active Total macrocell behavior I E /mv CSE Variation in open circuit potential characterizing local anodes in wet plastic grout and passive steel elsewhere. Differences in OCP develop macrocell corrosion.

13 Macrocell Corrosion Hardened Grout 5 Epoxy Cement Paste Titanium Ref and Aux Electrodes E /mvsce Hard Segregated Coupled l Time /dy Wet Plastic Interspersed with Hardened Grout Corrosion activity in wet plastic grout. Anodic polarization of active steel due to coupling with passive steel enhances corrosion rates. Icorr /ua 1 1 Coupled Segregated Hard Time /dy

14 15 1 A B C Imacro /ua Time /dy Large anodic macrocell currents developed in lab tests of field samples.

15 Role of Sulfate Ions E /V SCE E /mvsce I at 1mVSCE /ua Clean Pre rusted.6.7 ph E 9 1.E 8 1.E 7 1.E 6 1.E 5 1.E 4 1.E 3 I /A.1 3.E 5.1 SPS A SPS B SPS A SPS B SPS A SPS B ppm sodium sulfate 2 ppm sodium sulfate 2 ppm sodium sulfate.1 2.5E E 5 cathodic anodic 2, ppm Na 2 SO 4 E /mvsce E /V SCE I /A 1.5E 5 1.E 5 ppm Na 2 SO 4 ph E 6.7 ph 13.3.E E 9 1.E 8 1.E 7 1.E 6 1.E 5 1.E 4 1.E Time /s I /A High sulfate concentrations appear to have negative impact on steel passivation.

16 2, ppm Na 2 SO 4 ph 13.3 ph 13.3 Corrosion activity measured in lab samples with high concentration of sulfates.

17 ..1 High RH ph: , ppm Na 2 SO E / V SCE C G1 V3 1 (High RH/12.6 ph + SO4) C G1 V3 2 (High RH/12.6 ph + SO4) Time / days C G1 V3 1 (High RH/12.6 ph + SO4) C G1 V3 2 (High RH/12.6 ph + SO4) Macrocell Current / ua High RH ph: , ppm Na 2 SO Time / days Corrosion activity measured in lab samples with high concentration of sulfates. Research is in progress to resolve the role of sulfates.

18 TENTATIVE PROPOSED CORROSION MECHANISM High water content was present in the grout. High water content carried higher concentrations of ionic species including sulfates and chloride ions. High concentrations of sulfurous compounds (sulfates in solution) were present in the grout. Segregated grout material provided poor corrosion protection for embedded strand that did not attain uniform stable passivity. Differential aeration condition present due to easy access to oxygen, vastly different moisture contents in localized regions, and strand interstitial spaces creating crevices. Accelerated corrosion was caused by macrocell coupling of local anodes in the strand embedded in segregated grout and extended cathode throughout the tendon. WORK IN PROGRESS Identifying physical parameters of grout segregation mechanism. Resolving role of chloride, sulfates, and ph on steel depassivation in deficient grout. Identifying possible corrosion after repairs of deficient tendons.

19 CONCLUSIONS Segregated grout material was observed in localized portions of the tendons, characterized as: wet plastic, white chalky, and sedimented grout. High water content (up to 7 wt%) was measured in grout from localized portions of the tendons where corrosion occurred. Chloride accumulation was apparent in grout with high water content but concentrations were lower than conventional critical chloride threshold concentrations. No significant drop in pore water ph was observed in limited amount of sampling. However, slight depression of pore water (ph>11) from the wet plastic grout was apparent. Sulfate concentrations in the grout pore water were as high as 97 ppm. Corrosion in segregated grout (signified by high moisture content, high porosity, and high sulfate concentrations) was likely accelerated due to macrocell coupling with extended cathode throughout the tendon.

20 ACKNOWLEDGMENTS The work and assistance by Dennis Baldi, Will Blanchard, Matt Brosman, Jason Burchfield, Pat Carlton, Charles Ishee, Marc Knapp, Awilda Merced, Richard Nalli, Juan Rafols, Nikita Reed, and Yongyang Tang is acknowledged here. Cooperative work with Michael Ahern, Andrew Gillis, Richard Lewis, Randy Poston, and Phillip Sharff and assistance by Marcus Lee and John Newton is also acknowledged. QUESTIONS???

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