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Corrosion of reinforcing steel is the most significant cause of deterioration of reinforced concrete structures. Exposure to de-icing salts, seawater and chloride-containing set accelerators can play a significant role in reinforcing steel corrosion. Long-term exposure to carbon dioxide is also cited as a contributor to the corrosion of steel in concrete as well.
Reinforced concrete structures can corrode if they are exposed to chlorides or if the pH of the concrete decreases over time. Arc-sprayed zinc coatings are versatile and can be used as part of a cathodic protection system to halt corrosion and extend service life. Arc-sprayed zinc coatings are multi-functional and can be used as part of impressed current cathodic protection systems or they can be used to provide galvanic cathodic protection.
This paper describes the development and use of arc-sprayed zinc coatings for cathodic protection of steel in reinforced concrete structures.
Arc-sprayed zinc coatings were first used in 1983 as part of an impressed current cathodic protection systems. Activated and inactivated arc-sprayed zinc coatings were first used for galvanic cathodic protection in 1988 System descriptions, project lists and performance data for arc-sprayed zinc in both impressed current cathodic protection and galvanic cathodic protection applications will be presented.
Oil and gas wells are highly corrosive environments because they contain H2S and CO2. The 13Cr martensitic stainless steel is widely used in the oil and gas industry because of high good corrosion resistance in CO2 gas wells. Generally, the addition of Mo increases the passivity of steel. However, the role of Mo in passive films has not been completely clarified.
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Impressed current rectifiers are the backbone of a pipeline operator’s cathodic protection (CP) systems. A rectifier’s ability to protect a large length of electrically continuous pipeline considerably improves efficiencies and reduces material costs as compared to galvanic systems. However, like galvanic anodes, impressed current anodes are a consumable asset, and require replacement at the end of their service life to ensure that the rectifier can continue to adequately protect the pipeline.
Galvanized protective coatings have been used for structural steel to mitigate steel corrosion in atmospheric exposures and chloride-rich marine environments. The galvanizing process involves dipping steel elements free of surface mill scale in a molten zinc bath where the diffusion of zinc into the steel matrix allows for zinc-iron alloy layers of decreasing zinc concentrations by depth to form in the steel. Oher elements such as tin, antimony and aluminum may be added to the galvanizing bath to control reaction rates, surface appearance and corrosion behavior. Hot-dipped galvanizing provides corrosion protection by developing a barrier layer and in certain conditions provide beneficial galvanic coupling of the zinc-rich layers to the steel.