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Procedia Engineering 161 (2016) 116 – 120

World Multidisciplinary Civil Engineering-Architecture-Urban Planning Symposium 2016,

WMCAUS 2016

Biological Corrosion in The Sewage System and The Sewage

Treatment Plant
Elzbieta Stanaszek-Tomala, Maria Fiertaka,*
a
PK Cracow University of Technology, 24 Warszawska St., 31-155 Cracow

Abstract

Biological corrosion of sewers and sewage treatment plants constitutes a serious problem and its effects result in the loss of billions
of dollars a year. It is generally acknowledged that corrosion of concrete caused by microorganisms is associated with their
production of sulphuric acid as the main metabolic product. The activity of the bacteria leads to the formation of the sulphur cycle
in the system, and consequently to the formation of sulphuric acid, whose presence causes corrosion of concrete. Moreover, the
presence of other organisms, such as nitrifying bacteria, fungi and organic acids also contributes to the degradation of the concrete.
This article discusses the mechanism caused by biogenic inorganic acids.
©
© 2016
2016TheTheAuthors. Published
Authors. by Elsevier
Published Ltd. This
by Elsevier Ltd. is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of WMCAUS 2016.
Peer-review under responsibility of the organizing committee of WMCAUS 2016
Keywords: sulphur bacteria; nitrifying bacteria; wastewater treatment plant; corrosion of concrete;

1. Main text

Durability of concrete structures can be reduced by a lot of different mechanisms, including chemical and physical
ones. Concrete at a sewage treatment plant may be exposed to simultaneous (concurrent) effect of these mechanisms
causing unexpectedly rapid degradation. Concrete at different parts of a sewage treatment plant may be exposed to
sulphuric acid produced by microorganisms, sulphates and chlorides – containing water, to permanent submersion in
water and constant flow, as well as to changeable temperatures of freezing and thawing. Occurrence of such conditions
may cause problems to concrete, including cement dissolution, macro- and micro-cracks, as well as chipping and

* Corresponding author. Tel.: +48 12 628-23-45; fax: +48 12 628-23-67.

E-mail address: estanaszek-tomal@pk.edu.pl

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of WMCAUS 2016
doi:10.1016/j.proeng.2016.08.507
 Elzbieta Stanaszek-Tomal and Maria Fiertak / Procedia Engineering 161 (2016) 116 – 120 117

corrosion of the reinforcing steel (Coating, 2011). This paper discusses the biological mechanism. Biological corrosion
at sewage treatment plants is caused by corrosive secretions (metabolic products) of microorganisms. The conditions
prevailing there are very good for rapid development of bacteria. Treatment plants are hardly ever completely filled
with sewage and as a result there is a lot of space above the water line for bacterial development and growth and
accumulation of gas products from sewage decomposition. Because of the unusual rate of bacterial proliferation,
enormous quantities are formed in a short time, causing a huge potential threat to the facility.

2. Bacteria – a factor of corrosion

As far as corrosion is concerned, the most significant sorts of bacteria are those that produce sulphur compounds as a
result of the metabolic process. Such action may produce compounds of acidic character that are aggressive to concrete
and steel or cast iron. Some bacteria also oxidise iron to iron ions, which makes the local environment considerably
more aggressive to carbon steel.
The most commonly occurring bacteria in sewage treatment systems include bacteria of the genus Thiobacillus. These
organisms grow and develop best at 25-35°C. They are able to oxidise sulphide, elemental sulphur, thiosulphate and
polythionates. Bacteria of the Thiobacillus species can be divided into two groups. Group one consists of those that
only grow at neutral pH values. They are responsible for the conversion of the elemental sulphur to sulphuric acid.
The other group grow at lower pH values and are able to use Fe2+ as an electron donor. In this other group, a
representative of which is the Thiobacillus thiooxidans species, of great significance is the growth at acidic pH values.
They develop best at pH from 2 to 5 and in under aerobic conditions. Thiobacillus intermedius is most active at pH in
the range from 3 to 7, and oxidises thiosulphate ions (S2O32-). Thiobacillus ferrooxidans occurs in aerobic conditions
and has a range of pH growth from 1.5 to 5. It can oxidise Fe2+ to Fe3+.
The local environment produced by microorganisms may become so acidic (acid reaction) that it will cause dissolution
of concrete ingredients and corrosion of steel and cast iron. Another major issue, especially due to the action of
Thiobacillus ferrooxidans, is the formation of insoluble iron oxyhydroxide that clogs pipes made of steel or cast iron
(Bizier, 2007)
Formation of sulphuric acid is the main problem associated with the presence of Thiobacillus. Formation of H2SO4 in
municipal sewage is a two-stage process, i.e. bacteria produce sulphide ions and hydrogen sulphide, and then the
products are metabolised by other bacteria in order to produce oxidised sulphur compounds, which react with water
to form the acid.
In the sludge layers that form in the sewage pipelines and on other surfaces of sewage systems, sulphate-
reducing bacteria (SRB) are generally present. SRB are anaerobic and remain dormant until a layer of sludge cuts off
the oxygen supply. Then anaerobic conditions develop. When this happens, depending on local conditions, SRB
metabolize sulphate ions – reducing them to sulphide ions (S2-). Sulphide ions react with hydrogen ions in the sewage
to produce hydrosulphide, also called bisulphite ion (HS-). Formation of hydrogen sulphide takes place at temperatures
above 15 °C. HS- ions react with water producing hydrogen sulphide (H2S) in the dissolved form. Hydrosulphide ions
acidify water, thereby increasing concentration of hydrogen ions. This accelerates the formation of HS- ion and
gaseous H2S [5]. Factors influencing the production of hydrogen sulphide include (Kanagawa et al., 2000) the
concentration of sulphides and pH at the value of 6. Hydrogen sulphide accounts for more than 90% of the dissolved
sulphides while at pH 8, less than 10% occur in the form of hydrogen sulphide.
Sulphur hydride coming from the solution is released into the atmosphere and produces the smell of rotten eggs.
Gaseous H2S acidifies damp surfaces in closed spaces, causing acid corrosion of the metal or concrete surfaces. H2S
combined with oxygen together form polythionic acids (H2SnO6, n=1-60) – a weak form of sulphuric acid.
Sulphate-reducing bacteria do not die off under aerobic conditions and can coexist with aerobic thionic bacteria that
absorb oxygen. This leads to a development of anaerobic conditions. Such coexistence enhances corrosive action of
the environment due to the absorption of oxygen [3].
Sulphur-oxidising bacteria (SOB) colonize on wet surfaces at pH above 9.5 and when oxygen is present. Aerobic SOB
are particularly active in the loose layers of the facility that are rich in nourishment. Such places are present just over
the water line. SOB use dissolved oxygen to metabolize H2S and other sulphides to sulphuric acid (H2SO4). SOB are
acid-forming, and above all the representative of the genus Thiobacillus. A lot of Thiobacillus species take part in
producing sulphuric acid in sewage installations. Different types of the Thiobacillus bacteria develop in diverse
118 Elzbieta Stanaszek-Tomal and Maria Fiertak / Procedia Engineering 161 (2016) 116 – 120

conditions, including pH. Each strain of bacteria decreases the pH of the substrate surface to the optimal range for the
inhabitation and the multiplication by another strain. This process is repeated by all the Thiobacilli strains, producing
a very acidic environment, pH of circa 1, and thereby promoting rapid corrosion. Specific bacteria also have enough
nutritive constituents in order to vegetate; H2S is also present as well as dissolved oxygen, which is required for
maintaining aerobic conditions, [14]. Figure 1 presents an example of bacteria-induced corrosion of a concrete pipe,
[14].

Fig.1 Acid corrosion of sewage pipe caused by sulphur bacteria [14].

As far as the surface of concrete is concerned, pH can drop from the initial value of 13 to even 6 as a result of a
microbiological attack. Concentration of sulphuric acid can amount to 5% and or even 10%. Such acid concentration
corresponds to a pH value <1.
Apart from the destruction of concrete tanks by sulphur bacteria, destruction in nitrification/denitrification tanks at
sewage treatment plants may take place, [8]. Autotrophic nitrifying bacteria include the Nitrosomonas, Nitrobacter,
Nitrospira and the Nitrosococcus species [1], [6]. In such aerated tanks, ammonia is oxidised in two stages to nitrates.
In the first stage, ammonia oxidises to nitrates (III) and then nitrate (III) oxidises to nitrates (V).

2 NH 4Cl  3O2 o 2 HNO2  2 HCl  2 H 2O oxidizing the ammonium ion

2 HNO2  O2 o 2HNO3 oxidizing the nitric acid III

(1)

The biogenic acid released in the process of nitrification of ammonia chloride acts more aggressively on calcium

compounds than as a result of direct action of ammonia chloride.

NH4Cl  2O2  Ca(OH)2 o Ca 2   Cl  NO3  3H2O

NH4Cl  2O2  CaCO3 o Ca 2   Cl  NO3  H2O  CO2

2 NH4Cl  Ca(OH)2 o Ca 2   2Cl  2NH3  2H2O

2 NH4Cl  CaCO3 o Ca 2   2Cl  2NH3  H2O  CO2

(2)
 Elzbieta Stanaszek-Tomal and Maria Fiertak / Procedia Engineering 161 (2016) 116 – 120 119

3. Biological corrosion of concrete elements

In biological and chemical corrosion at a sewage treatment plant and in sewer pipes, four basic mechanisms of
chemical degradation of concrete can be distinguished. These are namely attack by acids (biogenic acids), carbonation,
chloride corrosion and attack by sulphides, [4]. This paper will only describe the mechanism induced by the attack of
biogenic acids.
Acids react with concrete by an acid-base reaction (neutralisation). The acidic environment in the facilities is sulphuric
or nitric acid. The former is formed by the action of sulphur bacteria as a result of a reaction of hydrogen sulphide,
water and air. In the latter case, it is formed by the action of nitrogen bacteria and a reaction of nitrates, water and air.
The rate of neutralisation depends on the initial concentration of the acid and the kind of acid. The hardened cement
paste in concrete is very alkaline, it usually starts out with a pH above 12.5.
Following exposition to acids or acid solutions, the cement begins to react with the acid to produce water-soluble salts.
These are mostly calcium salts. Acid attack causes dissolution of the cement phase of the concrete and exposition of
the less soluble coarse aggregate material. The effect of acids on the aggregate material in the concrete depends on its
chemical nature and the type of acid. Even alkaline aggregates like dolomite usually dissolve more slowly than the
cement. Additionally, steel reinforcement is vulnerable to the action of the aggressive environment. Prolonged action
of a weak acid will be indicated by occurrence of rust (corrosion of the reinforcing steel), cracking and spalling of the
concrete. With aggressive acid action, there are no cracks in the concrete or spalling and only loose aggregates remain
there. The rate of attacks by acids depends on the kind, quantity and strength (pH) of the acid, as well as on the physical
parameters such as frequency or duration of exposure, temperature, flow rates, etc. Continuous removal of the soluble
compounds formed in the reaction by washing or leaching accelerates the attack. On the other hand, in no-flow
conditions the action of the acid can be inhibited as a result of the acid being neutralized by the concrete, [13].
As a result of the acid attack of concrete, the reaction compound is predominantly calcium sulphate or gypsum, which
is easily removed under flowing conditions. Initially, the gypsum seals the mineral material, and thereby its strength
increases. Concrete also reacts with other constituents of the cement, and in particular with those that contain
aluminium in their composition, [10]. Concrete vulnerable to corrosive action has considerable amounts of tricalcium
aluminate (C3A) in the cement. This compound reacts with sulphate ions to produce calcium sulphoaluminate or
ettringite. With continued expansion of the crystals, tension occurs causing crack formation until the material is
disintegrated completely. During crystallisation, ettringite increases its volume in relation to the volume of the
substrates. This process leads to bulging and in effect, the composite is burst from inside it. Superficial build-up of
ettringite is also possible. In the final stage, deterioration of the outer layer takes place, [11]. Higher concentrations of
sulphates usually lead to extensive destruction of the concrete. Under no-flow conditions, sulphate attack will be less
aggressive unless the sulphate concentration itself is high. However, in actual situations sulphate action can progress
rapidly because the environment is continuously replenished (replaced; constant flow). Concrete is then regularly
exposed to a fresh stream of the corrosive environment. Also, continuous alternate wetting and drying can take place.
The initial indication of sulphate attack are micro-cracks in the cement paste. These cracks then develop and expand
as the attack progresses. In the final process of degradation, the concrete disintegrates into powder, and once again
the exposed surfaces are subjected to exposure to the corrosive environment [12].
In the case of the action of nitrifying bacteria and formation of nitrate acid by them, the pH value in the
nitrification tank remains in the range of 6.6-7.5. However, a lower pH is formed on the surface, which is associated
with the acid production and the effect of mass transport in the nitrification biofilm covering the concrete [8]. Such
acid action causes partial dissolution and weakening of the cement paste leading to erosion of the concrete surface.
As the result, the thickness of the reinforcement coating may be reduced along with the durability of the structure.
The degree of degradation depends on the composition of the concrete. Disintegrated concrete presents a characteristic
microstructure on the surface, i.e. leached paste or a thick layer of calcite formed close to the surface occur, [8]. This
layer is formed as a result of a reaction between calcium oxide that is in the concrete and CO2 migrating from the
nitrogen biofilm to the concrete. The leached, porous layer of silica gel on the surface and the layer of calcite reduce
the diffusion coefficient. In this manner, they act as a buffer against the attacking carbon dioxide, which contributes
to the increased resistance of the concrete.
120 Elzbieta Stanaszek-Tomal and Maria Fiertak / Procedia Engineering 161 (2016) 116 – 120

4. Conclusions

In many cases, concrete structures are damaged by microbiological corrosion to the point at which necessary repairs
should take place after four years, which was followed by a total destruction after six years. In order to protect concrete
against microbiological attacks it is necessary to apply coatings that will make a barrier and will be resistant to the
effect of biogenic inorganic acids (sulphuric, nitrate) and organic ones. The most relevant features that such coatings
should be characterised by include resistance to acids, good adhesion to steel and concrete, the lack of permeability
as well as resistance to the effects of salts.

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