Localized corrosion of steel in alkaline solution with low-level chloride and elevated sulfate concentrations

Localized corrosion developed on post-tensioned steel strand in deficient grout, relating to elevated concentrations of sulfate ions. The deficient grout can also have low-level chloride ion concentrations below threshold values originating from the base materials. Open-circuit potential, linear polarization resistance (LPR), and electrochemical noise (EN) measurements were made on steel specimens exposed in saturated calcium hydroxide solution with 0.012 M Cl⁻, 0.04 M SO₄²⁻, or combined. Results showed that the combined presence of sulfates in low-level chloride alkaline solutions elevated the corrosion rate and the extent of corrosion pitting. The EN technique was shown to provide corrosion rate estimates consistent with LPR and was able to identify pitting characteristics. The outcomes of the research provides supporting evidence that analysis of deficient grout for chlorides alone may not capture the risk for corrosion and that corrosion associated with elevated sulfate concentrations can be exacerbated in presence of low-level chlorides.