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| Naji, M. |
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| Motta, Antonella |
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| Aletan, Dirar |
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| Mohamed, Tarek |
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| Petrov, R. H. | Madrid |
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| Rančić, M. |
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| Azevedo, Nuno Monteiro |
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Szmigiera, Elzbieta
Warsaw University of Technology
in Cooperation with on an Cooperation-Score of 37%
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article
Concrete corrosion in a wastewater treatment plant – A comprehensive case study
Abstract
The article presents an in-depth analysis of the mechanism leading to protective coating failure and concrete corrosion in the wastewater treatment plant. Losses of protective epoxy coatings over large areas and deep concrete deteriorations with a maximum depth exceeding 2 cm were found after just 2 years of service on the concrete elements of pre-treatment tanks. The research program consisted of design documentation analysis, environmental tests, laboratory concrete and coating tests, and in-situ diagnostics. Environmental tests included determining temperature distribution over pre-treatment tank walls, analyzing wastewater composition, and determining CO2, H2S, and NH3 concentration in wastewater vapors. Laboratory concrete and coating tests were conducted on cores taken from tank walls and consisted of: compressive strength and freeze-thaw resistance tests, sulfate-ion content and pH distribution over depth, phase composition research, and SEM observations. In-situ diagnostics included pull-off and rebound hammer tests. Substances marked in the wastewater were in the ranges typical for municipal sewage. Wastewater itself did not constitute a significant threat to coated tank walls. The main threat to concrete sourced from the microbial activity of sulfur-reducing and oxidizing bacteria, resulting in successive H2S release from wastewater and H2S oxidation to H2SO4 on tanks walls (microbially induced concrete corrosion). The research results indicate that concrete used in the construction of wastewater treatment plant tank walls was properly designed, placed, and cured. The root cause of coating failure lied in its high vapor permeability and lack of full resistance to sulfuric acid, which resulted in the fast diffusion of SO42− ions from the coating surface into the concrete structure, causing its expansion and leading to coating delamination and concrete destruction.