Microbiologically Induced Corrosion of Concrete and Protective Coatings in Gravity Sewers

Bio-corrosion in concrete sewer systems: Mechanisms and mitigation strategies

The deterioration of concrete sewer structures due to bio-corrosion presents critical and escalating challenges from structural, economic and environmental perspectives. Despite decades of research, this issue remains inadequately addressed, resulting in billions of dollars in maintenance costs and a shortened service life for sewer infrastructure worldwide. This challenge is exacerbated by the absence of standardized test methods and universally accepted mitigation strategies, leaving industries and stakeholders confronting an increasingly pressing problem. This paper aims to bridge this knowledge gap by providing a comprehensive review of the complex mechanisms of bio-corrosion, focusing on the formation and accumulation of hydrogen sulfide, its conversion into sulfuric acid and the subsequent deterioration of concrete materials. The paper also explores various factors affecting bio-corrosion rates, including environmental conditions, concrete properties and wastewater characteristics. The paper further highlights existing corrosion test strategies, such as chemical tests, in-situ tests and microbial simulations tests along with their general analytical parameters. The conversion of hydrogen sulfide into sulfuric acid is a primary cause of concrete decay and its progression is influenced by environmental conditions, inherent concrete characteristics, and the composition of wastewater. Through illustrative case studies, the paper assesses the practical implications and efficacy of prevailing mitigation techniques. Coating materials provide a protective barrier against corrosive agents among the discussed techniques, while optimised concrete mix designs enhance the inherent resistance and durability of the concrete matrix. Finally, this review also outlines the future prospects and challenges in bio-corrosion research with an aim to promote the creation of more resilient and cost-efficient materials for sewer systems.

Experimental Investigations of a Tunnel Lining Segment Strengthened by In Situ Spraying Mortar

After long-term operation, tunnel lining segments encounter various problems. Aiming at these problems, in this paper, we present a method of strengthening tunnel lining segments by in situ spraying mortar. An experimental study of the in situ spraying mortar was carried out to determine the compressive strength, flexural strength and interface properties (splitting tensile strength and shear strength) between concrete and H-70 mortar. The experimental results show that the mechanical properties of H-70 mortar are less dependent on the curing humidity than ordinary concrete under standard curing conditions, the 7-day compressive strength of H-70 is 55 MPa, which is 61% of the 28-day compressive strength. This shows that H-70 has high early strength and is very suitable for rapid reinforcement. The interface roughness has a significant effect on the splitting tensile strength, and it can be increased by chiseling to improve the bearing capacity of the strengthened structure. A full-scale loading experiment was carried out on the segment strengthened by in situ spraying mortar. The loading process, failure mode and ultimate bearing capacity of the strengthened structure were analyzed by full-scale loading experiment. The research shows that the ultimate bearing capacity of the tunnel segment strengthened by in situ spraying mortar increased significantly. The ultimate bearing capacity of the strengthened structure is 10% higher than that of the unstrengthened structure. The advantages and disadvantages of in the situ spraying-mortar strengthening method are analyzed in comparison with the internal-tension steel-ring strengthening method.

Flow cytometric approach to evaluate the impact of hydro-technical concrete compounds' release to the freshwater microbiome

The aim of this research was to test the potential of applying a flow cytometric procedure to evaluate the impact of concrete compounds' release to the freshwater microbiome. Cells from the collected samples were stained with a fluorogenic redox indicator dye that measures the redox potential of microbial cells. This novel approach was combined with the assessment of microorganisms' penetration into the internal structures of concrete using the Rose Bengal sodium salt staining. Rose Bengal staining revealed an intense fouling of the upper and side walls of the concrete cubes and also indicated the penetration of microorganisms inside the concrete as observed for the cubes' cross-sections. Flow cytometric cellular redox potential measurement revealed high percentages of active cells within the concrete's porous structures and in non-exposed water (32.7% and 30.2% of active cells) versus samples from exposed water and concrete's outer surfaces (6.8%, 6.1%, and 3.3% of active cells). The results demonstrated a detrimental impact of hydro-technical concrete on the vitality of microbial cells within the freshwater environment. Tested protocol by analyzing the physiology of microbial cells improved the functional description of complex communities to evaluate the fate of contaminants present in the concrete-based hydro-technical infrastructure.

Service Life Evaluation for RC Sewer Structure Repaired with Bacteria Mixed Coating: Through Probabilistic and Deterministic Method

Since a concrete structure exposed to a sulfate environment is subject to surface ion ingress that yields cracking due to concrete swelling, its service life evaluation with an engineering modeling is very important. In this paper, cementitious repair materials containing bacteria, Rhodobacter capsulatus, and porous spores for immobilization were developed, and the service life of RC (Reinforced Concrete) structures with a developed bacteria-coating was evaluated through deterministic and probabilistic methods. Design parameters such protective coating thickness, diffusion coefficient, surface roughness, and exterior sulfate ion concentration were considered, and the service life was evaluated with the changing mean and coefficient of variation (COV) of each factor. From service life evaluation, more conservative results were evaluated with the probabilistic method than the deterministic method, and as a result of the analysis, coating thickness and surface roughness were derived as key design parameters for ensuring service life. In an environment exposed to an exterior sulfate concentration of 200 ppm, using the deterministic method, the service life was 17.3 years without repair, 19.7 years with normal repair mortar, and 29.6 years with the application of bacteria-coating. Additionally, when the probabilistic method is applied in the same environment, the service life was changed to 9.2–16.0 years, 10.5–18.2 years, and 15.4–27.4 years, respectively, depending on the variation of design parameters. The developed bacteria-coating technique showed a 1.47–1.50 times higher service life than the application of normal repair mortar, and the effect was much improved when it had a low COV of around 0.1.

Review of Fiber Optical Sensors and Its Importance in Sewer Corrosion Factor Analysis

Adverse effects of wastewater on the hygiene of human and circumstances is a major issue in society. Appropriate refining systems with high efficiency is required to treat the wastewater. Sewage treatment plant plays a major and important role in conserving incredible nature of the environment. Microbiologically Induced Corrosion (MIC) is an important phenomenon in sewage structures which causes the deterioration of infrastructures. Huge capital has been spent and efforts have been made on wastewater treatment infrastructure to increase operating efficiency and reliability of compliance. The investments in reimbursement and maintenance of sewer structures upsurge with an increase in the rate of MIC. The focus of this review is to describe MIC in sewer structure and the factors influencing the corrosion such as the generation of Sulfuric acid (H2SO4), Relative Humidity (RH), pH of the concrete structure and temperature. Modern developments in the design of Fiber Optical Sensors (FOSs) for observing the parameters including pH, Hydrogen Sulfide (H2S), RH and temperature will be discussed.

Identification of controlling factors for the initiation of corrosion of fresh concrete sewers

The development of concrete corrosion in new sewer pipes undergoes an initiation process before reaching an active corrosion stage. This initiation period is assumed to last several months to years but the key factors affecting the process, and its duration, are not well understood. This study is therefore focused on this initial stage of the corrosion process and the effect of key environmental factors. Such knowledge is important for the effective management of corrosion in new sewers, as every year of life extension of such systems has a very high financial benefit. This long-term (4.5 year) study has been conducted in purpose-built corrosion chambers that closely simulated the sewer environment, but with control of three key environmental factors being hydrogen sulfide (H2S) gas phase concentration, relative humidity and air temperature. Fresh concrete coupons, cut from an industry-standard sewer pipe, were exposed to the corrosive conditions in the chambers, both in the gas phase and partially submerged in wastewater. A total of 36 exposure conditions were investigated to determine the controlling factors by regular retrieval of concrete coupons for detailed analysis of surface pH, sulfur compounds (elemental sulfur and sulfate) and concrete mass loss. Corrosion initiation times were thus determined for different exposure conditions. It was found that the corrosion initiation time of both gas-phase and partially-submerged coupons was positively correlated with the gas phase H2S concentration, but only at levels of 10 ppm or below, indicating that sulfide oxidation rate rather than the H2S concentration was the limiting factor during the initiation stage. Relative humidity also played a role for the corrosion initiation of the gas-phase coupons. However, the partially-submerged coupons were not affected by humidity as these coupons were in direct contact with the sewage and hence did have sufficient moisture to enable the microbial processes to proceed. The corrosion initiation time was also shortened by higher gas temperature due to its positive impact on reaction kinetics. These findings provide real opportunities for pro-active sewer asset management with the aim to delay the on-set of the corrosion processes, and hence extend the service life of sewers, through improved prediction and optimization capacity.

Biogenic acids produced on epoxy linings installed in sewer crown and tidal zones

In this study the biogenic acids generated by microbes on the surface of Bisphenol A epoxy mortar coupons were investigated for up to 30 months. The epoxy coupons were installed in six sewers in three city locations, Sydney, Melbourne and Perth. Coupons were installed in both the crown and the tidal zones of the sewers to capture the effect of location within the pipe on acid production. The coupons were retrieved approximately every 6 months to provide a dynamic analysis of the biogenic acid production. Our results reveal the colonisation of epoxy mortar by the more aggressive acidophilic bacteria occurred within six months to two years of their installation in the sewer pipes. Biogenic acid generation appear to occur homogeneously from the tidal zone to the crown of the sewer pipes. The reduction in the surface pH of the epoxy lining was supported by the successive growth of microbes beginning with fungi followed be neutrophilic and heterotrophic bacteria and finally by the acidophilic bacteria and the corresponding accumulation of organic and sulphuric acids attributed to these organisms. This study also revealed the potential inhibiting effects on the microbes induced by the accumulation of metabolic products on the epoxy surface. The accumulation of organic acids and H2S coincided with the growth and metabolism inhibition of fungi and acidophilic bacteria. These results provide insights into the microbial interaction and biogenic acids production that contribute to lining degradation and corrosion of concrete in sewer pipes.