Several coatings and linings have been examined and used for the protection of sewer concrete pipes, against mainly biogenic-provoked corrosion due to the production of bio-sulfuric acid, leading to the degradation of the pipes’ structure and eventually, to their collapse and need for costly replacement. This study aimed to examine the potential differences between five different magnesium hydroxide coatings, prepared from powders presenting different purity, surface area and pore size distribution, when applied as corrosion protection agents. These coatings were tested by using accelerated sulfuric acid spraying tests, both in dry and wet coating conditions. The coating adhesion ability and their microstructure were examined by the application of pull-off measurements and of SEM analysis, respectively and were found to present certain differences, regarding the adhesion ability and the surface morphologies. During the acid spraying procedure, the surface pH and the mass change of coated concrete specimens were recorded daily. The surface pH was reduced towards acidic values and the mass reduction approached almost −20% in comparison with the initial coating mass for certain cases. Additionally, the hardness and roughness of concrete surface under the coating layer (i.e., the interface between the coating and the surface) after four days of acid spraying, exhibited much smaller changes (due to protection) in contrast to the uncoated concrete specimens (used as blank/comparison experiments), which were found to be highly affected/corroded. The formation of concrete corrosion and coating by-products, as noticed after the respective chemical reactions, was recorded by X-ray diffraction (XRD) measurements and the respective quantification of obtained results. In all the coated specimens only very small amounts of the major by-product (gypsum) was observed, indicating that the concrete surface was sufficiently protected from sulfuric acid attack.

The biological activity occurring in urban sewerage systems usually leads to the (biogenic) corrosion of pipe infrastructure. Anti-corrosion coating technology was developed in an effort to protect sewer pipes from degradation. This study evaluates a new class of relatively low-cost magnesium hydroxide-based coatings, regarding their ability to adhere efficiently onto the concrete surface, and offer efficient corrosion protection. Six magnesium hydroxide-based coatings were prepared with the addition of two different types of cellulose, used as adhesion additives, and these were applied on concrete specimens. Pull-off measurements showed that the addition of higher amounts of cellulose could improve the coating adhesion onto the concrete surface. An accelerated sulfuric acid spraying test was used to evaluate the consumption time of the applied coatings and their efficiency in maintaining over time slightly alkaline pH values (above 8) on the coated/protected surfaces. At the end of spraying test, a mineralogical analysis of surface samples was performed, indicating that the formation of corrosion by-products (mainly gypsum) was increased when the added amount of cellulose was lower. Hardness and roughness measurements were also conducted on the concrete surfaces, revealing that the coatings helped the concrete surface to preserve its initial surface properties, in comparison to the uncoated specimens. A SEM/microstructure analysis showed that aggregates were formed (possibly consisting of Mg(OH)2), affecting the reactivity of the protected surface against sulfuric acid attack.

The purpose of the present work was to study the corrosion protection that relatively low-cost magnesium hydroxide coatings offer to concrete by stabilizing the surface pH. To facilitate the material’s adhesive ability, methyl-cellulose and carboxymethyl-cellulose were used as environmentally friendly additives in three different concentrations, 1, 0.4 and 0.1 wt.% of solids, respectively. The coatings were applied on the surface of concrete blocks, in two different coating thicknesses. A sulfuric acid solution was used to simulate the biologically produced acid in sewer pipes. Sulfuric acid was sprayed on the specimens, while the total amount of acid sprayed was calculated, in order to correspond to a specific reaction’s stoichiometry daily. The surface pH of coated specimens was monitored daily with a surface pH meter. The gypsum production was studied with X-ray diffraction, to evaluate the coatings’ protection. The experimental time period that coatings were consumed was compared with the theoretically consumption time.

The Microbiologically Induced Corrosion (MIC) of concrete sewer pipes is a commonly known problem that can lead to the destruction of the system, creating multiple public health issues and the need for costly repair investments. The present study focuses on the development of a magnesium hydroxide coating, with optimized properties to protect concrete against MIC. The anti-corrosion properties of the respective coating were evaluated by using short and long duration accelerated sulfuric acid spraying tests. The coating presented satisfying adhesion ability, based on pull-off and Scanning Electron Microscopy (SEM) analysis measurements. The surface pH of the coated concrete was maintained at the alkaline region (i.e., >8.0) throughout the duration of all acid spraying tests. The consumption of the coating, due to the reaction (neutralization) with sulfuric acid, was confirmed by the respective mass and thickness measurements. The protection ability of this coating was also evaluated by recording the formation of gypsum (i.e., the main corrosion product of concrete) during the performed tests, by X-ray Diffraction (XRD) analysis and by the Attenuated Total Reflectance (ATR) measurements. Finally, a long duration acid spraying test was additionally used to evaluate the behavior of the coating, simulating better the conditions existing in a real sewer pipe, and the obtained results showed that this coating is capable of offering prolonged protection to the concrete substrate.

Abstract:The purpose of the present work was to study the corrosion behavior of steel coated with epoxy-(organo) clay nanocomposite films. The investigation was carried out using salt spray exposures, optical and scanning electron microscopy examination, open circuit potential, and electrochemical impedance measurements. The mechanical, thermomechanical, and barrier properties of pristine glassy epoxy polymer and epoxy-clay nanocomposites were examined. The degree of intercalation/exfoliation of clay nanoplatelets within the epoxy polymer also was determined. The mechanical, thermomechanical, and barrier properties of all the epoxy-clay nanocomposites were improved compared to those of the pristine epoxy polymer. In addition, both the pristine epoxy and the epoxy nanocomposite coatings protected the steel from corrosion. Furthermore, the protective properties of the nanocomposite coatings were superior compared to those of the pristine epoxy polymer. The protective properties of the nanocomposite coatings varied with the modified clay used. The epoxy-montmorillonite clay modified with primary octadecylammonium ions, Nanomer I.30E, had a better behavior than that modified with quaternary octadecylammonium ions, Nanomer I.28E.

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