Real-Time Corrosion Monitoring in a Potable Water Tank: Towards Predictive Maintenance and Durability Limit States

This paper presents a full-scale case study on real-time corrosion monitoring in an underground reinforced-concrete potable water tank built in 1968. The study aims to demonstrate how continuous electrochemical monitoring can support durability assessment and predictive maintenance in ageing water-retaining infrastructure, where direct inspection is often limited and exposure conditions are spatially variable. Fourteen monitoring points were installed in beams, columns and domes subjected to different exposure conditions. Corrosion potential, concrete resistivity, corrosion current density and temperature were recorded every 3 h and used to assess the corrosion state of the reinforcement. The monitored durability indicators were reinforcement section loss, estimated from corrosion current density using Faraday’s law, and corrosion-induced crack-width evolution, used as a serviceability-related indicator for maintenance planning. The results show that beams remained predominantly passive, with corrosion current densities below 0.1 µA/cm2 and incremental sectional losses below approximately 2 µm during the monitoring period. Columns showed the highest vulnerability, particularly at lower elevations subjected to prolonged immersion, with estimated incremental section losses reaching approximately 4–6 µm and a clear correlation between submerged time and corrosion progression. Domes exhibited intermediate behaviour, with occasional activation events associated with environmental fluctuations. A multivariable model combining resistivity and temperature was used to interpret corrosion kinetics, while Faraday-based section-loss estimates were coupled with empirical crack-width models to forecast serviceability indicators up to 2045. These forecasts are presented as scenario-based maintenance-support indicators rather than deterministic predictions of future damage, since corrosion propagation and crack development may evolve nonlinearly under changing exposure conditions. The proposed approach demonstrates how continuous corrosion monitoring can be linked to durability limit-state assessment, enabling risk-informed and performance-based maintenance of critical water infrastructure.