Experimental Investigation on the Tensile and Bond Durability of Galvanized Steel Reinforced Grout

Steel reinforced grout (SRG) composites are widely used for strengthening existing structures. Galvanized (zinc-coated) ultra-high tensile strength steel cords are more durable than brass-coated and cheaper than stainless-steel ones, making them the most common in practice. While compliant with certification standards, corrosion may occur, potentially affecting tensile strength and bond capacity. The latter has, however, remained largely unexplored, highlighting a need to assess durability under different environmental exposures. This study investigated the durability of galvanized SRGs with four cord types and four mortar matrices (cement- and lime-based). Direct tensile, shear bond, and lap-tensile tests were conducted after immersion in saltwater or alkaline solutions, exposure to freeze–thaw or salt crystallization cycles, and high temperatures. Results highlighted salt exposure as the most critical condition, particularly with lime-based matrices. Zinc coating thickness proved essential for corrosion resistance, while freeze–thaw and salt crystallization led to bond degradation due to concentrated steel corrosion and mortar microcracking. The findings highlight the importance of considering appropriate protective measures and exposure-specific conditions when designing SRG reinforcements.