Based on the results of laboratory testing, the initial galvanization coating was likely greater than the specified thickness of 2.0 oz/ft2 (86 μm). The zinc galvanization is corroding at a slower rate than the AASHTO design rate. The AASHTO design rate for depletion of zinc coating and subsequent corrosion of the steel reinforcement is conservative for the corrosion conditions present in the MSE wall reinforcement coupons tested. The integrity of the steel reinforcement that is currently in place is not likely to be compromised by corrosion.
The primary objective of this study was to extract reinforcement coupons from select MSE walls and document the extent of corrosion. A secondary objective of this project was to develop and assess techniques for removal of coupons on two-stage MSE walls.
ABSTRACT: Mechanically stabilized earth (MSE) walls are a more advanced form of a retaining wall, often larger and able to hold back more backfill. This is achieved by reinforcing strips or meshes (most often galvanized steel) placed into the soil, which are held in place by friction. The strips mechanically stabilize the earth while undergoing tension. The wall is covered with concrete medallions that connect to the reinforcements. The medallions have only a secondary structural role in holding up the wall but provide cover that protects the soil from washing away. MSE walls are structures expected to have very long service lives (e.g. 100 years). Confirmation is needed that such durability can be achieved, especially to show that the progression of corrosion of the reinforcement is slow enough. Ten MSE walls around Florida were instrumented (electrical connections were made through the concrete covers to the buried elements) between 1996- 1998 and used to survey corrosion rates of galvanized strip or mesh soil reinforcements. Initial estimates of corrosion-related durability were obtained at that time, indicating a good prognosis for long term durability. The objective of the research in this thesis was to obtain additional indications of the durability of reinforcements in MSE walls in Florida so as to perform a more reliable projection of future performance. Corrosion behavior was measured at the same locations as the initial survey by electrochemical nondestructive tests and by destructive tests. The nondestructive testing consisted of half-cell potentials, polarization resistance measurements, and electrochemical impedance spectroscopy. Corrosion rates reported in this thesis are based upon polarization resistance measurements. The destructive testing consisted of soil extraction and hardware extraction. Hardware extraction enabled independent verification of estimates of electrochemical corrosion rate. Analysis of extracted soil verified that soil composition was within construction specifications. The data from the current survey were also used to further improve prediction of corrosion. The present series of evaluations confirm that the structures are performing as desired based upon the updated model projection of future corrosion.
The inability of soil to provide sufficient tensile strength presents challenges for soils being used as a structural building material. However, it is possible to improve the structural performance with the inclusion of a reinforcing system. The development of these systems has been a major advancement of the civil engineering practice. Mechanically stabilized earth (MSE) wall systems typically consist of a: concrete facing panel, specified backfill, reinforcing elements, and the retained fill. The interaction of the backfill with the reinforcements, and the reinforcements with the facing panels, produces a system that when properly designed, can be a cost effective engineering solution. In Nevada there are over 150 MSE walls that have been constructed using metallic reinforcements (Thornley 2009). Corrosion of metallic elements a naturally occurring electrochemical process is irreversible an inevitable. The rate of metal loss (corrosion) is a function of the environmental conditions and metal type. For MSE walls key parameters include the backfill's: salt content, organic content, saturation level, as well as the metal type of the reinforcements. Nevada has two previous corrosion investigations, an extensive site investigation at I-515/ Flamingo Rd. and a statistical analysis of as-built soil records along with a preliminary investigation for I-15/ Cheyenne Blvd. These studies form the foundation for this investigation of in-situ corrosion conditions. Seven MSE wall sites were investigated using electrochemical backfill characterization and linear polarization resistance (LPR) corrosion rate monitoring. Evaluation of electrochemical backfill characteristics has resulted in the discovery of six sites that fail current NDOT/ AASHTO MSE wall backfill requirements. The in-situ soil samples collected and analyzed more than doubled the available data used to describe the corrosiveness of the backfill. Linear polarization resistance corrosion rates were obtained for more than 200 different elements. These data suggest that despite the aggressive nature of the backfill, most elements are preforming well and are below the anticipated rates. However, several elements were discovered with corrosion rates in excess of five times the design model. The use of the LPR corrosion monitoring has concluded that the conditions at I-15/ and Cheyenne Blvd. are equivalent to or worse than the conditions evaluated in 2004 at the I-515/ Flamingo Rd. complex. The discoveries at Flamingo Rd. led to remediation of the largest wall at the complex. Through the use of electrochemical backfill characteristics and LPR corrosion rates, the seven sites investigated have been ranked. The rankings are dependent on several factors such as backfill electrochemical conditions and comparison of corrosion rates data with design models. This study has confirmed that observations of conditions along the exterior of the wall are not sufficient when determining the condition of the soil reinforcements. Routine corrosion monitoring is required to monitor the depletion of the soil reinforcements and should be incorporated into a Long-term Corrosion Monitoring and Asset Management Plan (LCMAMP). It is anticipated that a program will be integrated into Nevada's current asset management systems. The development and implementation of LCMAMP, directly reflects the federal initiative for systematic detailed evaluation of critical assets, MAP-21.
This project provided information and recommendations for material selection for best corrosion control of reinforcement in mechanically stabilized earth (MSE) walls with void repairs. The investigation consisted of small- and large-scale experiments and modeling to examine corrosion aggravation effects and conduct durability projections.
Mechanically Stabilized Earth (MSE) retaining walls have become the dominant retained wall system on ODOT projects. The permanent MSE walls constructed on ODOT projects, in recent years, use metallic reinforcements and facing connections buried directly in the backfill soil. Accelerated deterioration of these structural elements would have serious financial and safety impacts for the Department. Classical MSE wall design incorporates an estimate of deterioration of reinforcement by corrosion. Monitoring of actual corrosion performance, however, is an important element of managing the current inventory of MSE walls. Monitoring could answer key questions that can provide for the best management of the existing walls, and provide feedback to the design process for future installations. This report details a literature review of methods for estimating and measuring deterioration of structural reinforcing elements in both concrete and MSE walls. It also presents a selected history of metallic reinforcement design specification and utilization. A listing of the MSE walls that can be identified in the ODOT Bridge Data System is included.
Corrosion Atlas Case Studies: 2023 Edition gives engineers expedient daily corrosion solutions for common industrial equipment no matter the industry. Providing a purely operational level view, this reference is designed as concise case studies categorized by material and includes content surrounding the phenomenon, equipment appearance supported by a color image, time of service, conditions, cause and suggested remedies. Additional reference listings for deeper understanding beyond the practical elements are also included. Rounding out with an introductory foundational layer of corrosion principles critical to all engineers, this book delivers the daily tool required for engineers today to solve their equipment's corrosion problems. Corrosion engineers today spend enormous amounts of time and money searching multiple detailed sources and variable industry-specific standards to locate known remedies to corrosion equipment problems. Corrosion Atlas Series is the first centralized collection of case studies containing challenges paired directly with solutions together in one location. The third release of content in the series, - Solves equipment failure with easy-to-find remedies organized by essential elements such as materials, system, part, cause, environmental, and phenomenon - Grasps fundamental corrosion elements on all major industrial pieces of equipment - Identifies failures by appearance with color figures within each case study - Provides correlation between avoiding corrosion and net zero
Mechanically Stabilized Earth (MSE) wall is a civil structure that has been used for various purposes e.g., supporting bridges, residential or commercial buildings, roadways, railroads etc. In general, MSE wall uses either metal strip, bar or geosynthetics materials as reinforcement. Roger et al. (2010) mentioned that an approximately 57% of the MSE wall constructed in U.S. utilize steel strips as the resources of reinforcement. The usage of metal steel strips is followed by usage of steel bar mats (24%) and geosynthetics grids (18%). Even though MSE walls are designed for a service life of 75 to 100 years, early complication has often been reported. Corrosion of the reinforced steel has been the major cause that afflicts the long-term performance of these walls. The deicing salts used on pavements to melt down snow is one of the major cause of corrosion of these reinforced steels. The aggressiveness of deicers in terms of corrosion of these reinforced steel is studied through the potentiodynamic polarization technique at various concentrations. This study aims to determine the corrosion behavior on galvanized steel and bare steel in presence of individual deicing salt or deicers e.g., sodium chloride, calcium chloride, magnesium chloride and potassium acetate at various (i.e., 0.25, 0.50 and 1.0 M) concentration. Subsequently, the surface morphology was analyzed by using Scanning Electron Microscopy (SEM) and the mineralogical composition was observed through X-Ray Diffraction (XRD). In addition, the corrosivity of two backfill aggregates, natural aggregate and recycled concrete aggregate, was compared. The result shows that the corrosion effect of deicers on reinforced steel depends on its chemical composition and concentration. The SEM imaging showed the presence of micro cracks on the surface of galvanized steel, resulting in pitting corrosion rather than general surficial corrosion. Comparing the corrosion rate of these deicers, the aggressiveness of these deicers on galvanized steel can be arranged in the following order: sodium chloride > calcium chloride > magnesium chloride > potassium acetate. Although sodium chloride was most aggressive for both the steel, the aggressiveness of these deicers on bare steel was different from that of galvanized steel and can be arranged in following order: sodium chloride > magnesium chloride > calcium chloride > potassium acetate. The pH and electrical resistivity of the natural and recycled aggregates were compared with standard provided by American Association of State Highway and Transportation Officials (AASHTO) and found to be non-corrosive. The corrosion rate of both the aggregates on galvanized and bare steel were inappreciable. While analyzing the corrosiveness of these two aggregates, recycled concrete aggregate was observed to be more aggressive than the natural aggregate.
