Title:
Corrosion Resistance of Unbonded Post-Tensioning Tendons with Construction Defects
Author(s):
In-Seok Yoon, Hyeongyeop Shin, and Thomas H.-K. Kang
Publication:
Structural Journal
Volume:
122
Issue:
6
Appears on pages(s):
183-197
Keywords:
construction defects; corrosion resistance; electrochemical method; grouted extruded-strand (GES) tendon; high-density polyethylene (HDPE) sheath; unbonded post-tensioning
DOI:
10.14359/51746823
Date:
9/1/2025
Abstract:
Corrosion of prestressing steel can threaten the durability of prestressed concrete. To ensure the durability of unbonded post-tensioning (PT) systems, it is crucial to investigate the effects of construction defects such as grease leakage and high-density polyethylene (HDPE) sheath damage. This study quantified the thickness of grease coating (PT coating) and HDPE sheath damage as experimental variables. An accelerated corrosion test was conducted in two environments: 1) chloride ions only (Cl–); and 2) both chloride ions and dissolved oxygen (Cl– + DO). The corrosion current density and weight loss of prestressing strands and the suspended concentration density of corrosion cell solution were measured to quantify the corrosion performance. Increasing the grease coating thickness over 0.3 mm (0.012 in.) did not significantly enhance corrosion resistance. Realistic levels of HDPE sheath damage had no significant detrimental effects on durability; however, excessive HDPE sheath area loss must be avoided for long-term durability. It was examined to quantify the interrelationship between three data—electrochemical measurement, weight-loss, and suspended concentration density—as quantitative corrosion data. The findings of this study can serve as a basis for developing durability-related provisions, as well as controlling the construction defects of unbonded PT systems in field applications.
Related References:
1. Yoon, I. S.; Çopuroğlu, O.; and Park, K.-B., “Effect of Global Climatic Change on Carbonation Progress of Concrete,” Atmospheric Environment, V. 41, No. 34, 2007, pp. 7274-7285. doi: 10.1016/j.atmosenv.2007.05.028
2. Yoon, I. S., and Chang, C., “Quantitative Relationship between Chloride Penetration Depth and Hydraulic Conductivity of Concrete under Hydrostatic Pressure,” Journal of Materials in Civil Engineering, ASCE, V. 34, No. 5, 2022, p. 04022074. doi: 10.1061/(ASCE)MT.1943-5533.0004198
3. Monfore, G. E., and Verbeck, G. J., “Corrosion of Prestressed Wire in Concrete,” ACI Journal Proceedings, V. 57, No. 11, Nov. 1960, pp. 491-516.
4. Nürnberger, U., “Corrosion Induced Failure Mechanisms of Prestressing Steel,” Materials and Corrosion, V. 53, No. 8, 2002, pp. 591-601. doi: 10.1002/1521-4176(200208)53:83.0.CO;2-X
5. Trejo, D.; Pillai, R. G.; Hueste, M. B. D.; Reinschmidt, K. F.; and Gardoni, P., “Parameters Influencing Corrosion and Tension Capacity of Post-Tensioning Strands,” ACI Materials Journal, V. 106, No. 2, Mar.-Apr. 2009, pp. 144-153.
6. Perrin, M.; Gaillet, L.; Tessier, C.; and Idrissi, H., “Hydrogen Embrittlement of Prestressing Cables,” Corrosion Science, V. 52, No. 6, 2010, pp. 1915-1926. doi: 10.1016/j.corsci.2010.02.041
7. Yoon, I. S.; Kang, T. H.-K.; and Shin, H., “Corrosion Protection Method and Performance for Prestressing Strands,” Heron, V. 64, No. 1-2, 2019, pp. 39-56.
8. Schupack, M., and Suarez, M. G., “Some Recent Corrosion Embrittlement Failures of Prestressing Systems in the United States,” PCI Journal, V. 27, No. 2, 1982, pp. 38-55. doi: 10.15554/pcij.03011982.38.55
9. Woodward, R. J., and Williams, F. W., “Collapse of Ynys-Y-Gwas Bridge, West-Glamorgan-Discussion,” Proceedings of the Institution of Civil Engineers Part 1-Design and Construction, V. 86, 1989, pp. 1177-1191.
10. Hartt, W. H., and Venugopalan, S., “Corrosion Evaluation of Post-Tensioned Tendons on the Mid Bay Bridge in Destin, Florida,” Florida Department of Transportation, Tallahassee, FL, 2002.
11. Seoul Metropolitan Government, “Report of Establishment of Maintenance Plan for Tension Material of Psc Box Girder Bridge in Seoul,” Seoul, Korea, 2017. (in Korean)
12. Pacheco, A. R.; Schokker, A. J.; and Hamilton, H. R. III, “Revisions to Accelerated Corrosion Test Method for Post-Tensioning Grout,” ACI Materials Journal, V. 104, No. 2, Mar.-Apr. 2007, pp. 123-128.
13. Pacheco, A. R.; Schokker, A. J.; Volz, J. S.; and Hamilton, H. R. III, “Linear Polarization Resistance Tests on Corrosion Protection Degree of Post-Tensioning Grouts,” ACI Materials Journal, V. 108, No. 4, July-Aug. 2011, pp. 365-370.
14. Schokker, A. J.; Breen, J. E.; and Kreger, M. E., “Grouts for Bonded Post-Tensioning in Corrosive Environments,” ACI Materials Journal, V. 98, No. 4, July-Aug. 2001, pp. 296-305.
15. Yoo, D. Y.; Ryu, G. S.; Yuan, T.; and Koh, K. T., “Mitigating Shrinkage Cracking in Posttensioning Grout Using Shrinkage-Reducing Admixture,” Cement and Concrete Composites, V. 81, 2017, pp. 97-108. doi: 10.1016/j.cemconcomp.2017.05.005
16. Jaeger, B. J.; Sansalone, M. J.; and Randall, W. P., “Detecting Voids in Grouted Tendon Ducts of Post-Tensioned Concrete Structures Using the Impact-Echo Method,” ACI Structural Journal, V. 93, No. 4, July-Aug. 1996, pp. 428-438.
17. Matt, P., “Non-Destructive Evaluation and Monitoring of Post-Tensioning Tendons,” fib Bulletin 15, 2001, pp. 103-108.
18. Iyer, S.; Schokker, A. J.; and Sinha, S. K., “Ultrasonic C-Scan Imaging: Preliminary Evaluation for Corrosion and Void Detection in Posttensioned Tendons,” Transportation Research Record: Journal of the Transportation Research Board, V. 1827, No. 1, 2003, pp. 44-52. doi: 10.3141/1827-06
19. AASHTO, AASHTO LRFD Bridge Construction Specifications, 4th Edition, American Association of State Highway and Transportation Officials, Washington, DC, 2017.
20. ASME, ASME Boiler and Pressure Vessel Code, Section Iii. Rules for Construction of Nuclear Facility Components, Division 2. Code for Concrete Containments, American Society of Mechanical Engineers, New York, NY, 2021.
21. PTI Committee M55, “Specification for Grouting of Post-Tensioned Structures (PTI M55.1-12),” Post-Tensioning Institute, Farmington Hills, MI, 2012, 53 pp.
22. ACI Committee 318, “Building Code Requirements for Structural Concrete (ACI 318-19) and Commentary (ACI 318R-19) (Reapproved 2022),” American Concrete Institute, Farmington Hills, MI, 2019, 624 pp.
23. PTI/ASBI, “Guide Specification for Grouted Post-Tensioning (PTI/ASBI M50.3-12),” Post-Tensioning Institute, Farmington Hills, MI, 2012.
24. NRC, “Qualifications for Cement Routing for Prestressing Tendons in Containment Structures,” Regulatory Guide 1.107, Nuclear Regulatory Commission, Rockville, MD, 2011.
25. Agrawal, S. K.; Chauhan, A.; and Mishra, A., “The Vvers at Kudankulam,” Nuclear Engineering and Design, V. 236, No. 7-8, 2006, pp. 812-835. doi: 10.1016/j.nucengdes.2005.09.030
26. Domage, J.-B.; Ruffray, N.; and Elias, S., “Full Scale Post-Tensioning Mock-up to Illustrate New Technologies for Nuclear Containments,” Proceedings, Technical Innovation in Nuclear Civil Engineering - TINCE 2013, Paris, France, 2013.
27. Isard, C.; Zivanovic, I.; Verdoux, M.; Diaz, S.; Courtois, A.; and Lambert, E., “Prestressing Tendons with Individually Greased and Sheathed Strands for the Design of Future NPP,” Proceedings, Technical Innovation in Nuclear Civil Engineering - TINCE 2013, Paris, France, 2013.
28. NEA/CSNI/R, (2015)5, “Bonded or Unbonded Technologies for Nuclear Reactor Prestressed Concrete Containments,” Organisation for Economic Co-Operation and Development, Paris, France, 2015, 227 pp.
29. Shin, H.; Kang, T. H.-K.; and Park, J. H., “Grouted Extruded-Strand Tendons: Friction Coefficients and Differential Individual Strand Forces,” ACI Structural Journal, V. 117, No. 3, May 2020, pp. 223-233.
30. Shin, H., “Behavior of Greased-Sheathed Strand Tendons in Post-Tensioned Structures with Grouted Duct,” PhD dissertation, Department of Architecture and Architectural Engineering, Seoul National University, Seoul, Korea, 2024.
31. Shin, H.; Lee, D.; and Kang, T. H.-K., “Web-Crushing Strength of Post-Tensioned Members with Grouted Extruded-Strand Tendons,” Construction and Building Materials, V. 458, 2025, pp. 1-16. doi: 10.1016/j.conbuildmat.2024.139552
32. Joint ACI-ASCE Committee 423, “Specification for Unbonded Single-Strand Tendon Materials and Commentary (ACI 423.7-14),” American Concrete Institute, Farmington Hills, MI, 2014, 8 pp.
33. EOTA, “Guideline for European Technical Approval of Post-Tensioning Kits for Prestressing of Structures (ETAG013),” European Organisation for Technical Approvals, Brussels, Belgium, 2002.
34. Hamilton, H. R. III; Breen, J. E.; and Frank, K. H., “Bridge Stay Cable Corrosion Protection. II: Accelerated Corrosion Tests,” Journal of Bridge Engineering, ASCE, V. 3, No. 2, 1998, pp. 72-81. doi: 10.1061/(ASCE)1084-0702(1998)3:2(72)
35. Clear, K. C., “Measuring Rate of Corrosion of Steel in Field Concrete Structures,” Transportation Research Record, V. 1211, 1989, pp. 28-37.
36. Yoon, I. S.; Shin, H.; and Kang, T. H.-K., “Comparative Study on Performance of Corrosion Protective Systems for Post-Tensioned Concrete Members,” ACI Structural Journal, V. 116, No. 3, May 2019, pp. 273-284. doi: 10.14359/51715513
37. Schupack, M., “Corrosion Protection for Unbonded Tendons,” Concrete International, V. 13, No. 2, Feb. 1991, pp. 51-57.
38. Ashar, H., and Bagchi, G., “Assessment of Inservice Conditions of Safety-Related Nuclear Plant Structures,” U.S. Nuclear Regulatory Commission, Rockville, MD, 1995.
39. Shin, H.; Kang, T. H.-K.; and Park, J.-H., “ASME B&PV Code and ACI Standard 359 Tendon Installation Revision Proposal,” PTI Journal, V. 15, No. 2, 2019, pp. 5-17.
40. Stern, M., and Geary, A. L., “A Theoretical Analysis of the Shape of Polarization Curves,” Journal of the Electrochemical Society, V. 104, No. 1, 1957, pp. 56-63. doi: 10.1149/1.2428496
41. Andrade, C., and González, J., “Quantitative Measurements of Corrosion Rate of Reinforcing Steels Embedded in Concrete Using Polarization Resistance Measurements,” Materials and Corrosion, V. 29, No. 8, 1978, pp. 515-519. doi: 10.1002/maco.19780290804
42. Broomfield, J. P., “Corrosion Rate Measurements in Reinforced Concrete Structures by a Linear Polarization Device,” Concrete Bridges in Aggressive Environments, SP-151, R. E. Weyers, ed., American Concrete Institute, Farmington Hills, MI, 1994, pp. 163-182.
43. ASTM G1-03, “Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test Specimens,” ASTM International, West Conshohocken, PA, 2003, 9 pp.
44. Cussler, E. L., Diffusion: Mass Transfer in Fluid Systems, Cambridge University Press, New York, 2009.
45. Andrade, C., “Propagation of Reinforcement Corrosion: Principles, Testing and Modelling,” Materials and Structures, V. 52, No. 1, 2019, p. 2. doi: 10.1617/s11527-018-1301-1