NEW GENERATION STAINLESS

STEEL REINFORCING BARS FOR

CONCRETE STRUCTURES

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CONTENTS
1. Introduction
2. Causes of corrosion
3. Stainless steel
4. Types of stainless steel
5. Cost of stainless steel
6. Applications
7. Conclusion
8. References

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Introduction

 Construction builds the basic framework and infrastructure of a country

 Reinforced concrete has been used successfully in the construction

industry since the beginning of this century

 One of the products traditionally used to reinforce concrete is plain

carbon steel

 Large number of reinforced structures are starting to show serious signs

of deterioration, particularly those over 30 years of age due to corrosion
of reinforcement

 This necessitates costly and time-consuming repairs and maintenance of

the structure

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What Causes Corrosion?

 Chloride ion is the main culprit

 Chlorides may be incorporated into the original mix due to their

presence in the sand, aggregate or water. Chlorides penetrate
through the "cover" when the external surfaces of the concrete
are exposed to seawater, marine atmospheres or de-icing salts

 When steel corrodes, it forms an oxide layer. These corrosion

products-oxides-have a larger volume than the original steel.
This expansion puts pressure on the concrete cover. Since the
concrete is already set and hard, it causes cracks as it expands to
accommodate the larger volume of steel inside

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Some Pictures Showing the Deterioration of Structures Due to
Carbon Steel Reinforcement

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Several Methods Are Currently Employed in an Attempt to Reduce
the Corrosion of Carbon Steel Rebars.
 Rebar coatings
 Increased concrete cover
 Reduced water/cement ratios
 Corrosion inhibiting admixtures added to the concrete mix
 Cathodic protection
 Application of waterproofing membranes, penetrants and
sealers on concrete surfaces

Solution lies in providing the stainless steel which is resistant

to corrosion
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What Is Stainless Steel?
 Stainless steel is low carbon steel. It is an alloy of iron with chromium content over
10.5%.Also nickel,molybdenum and certain other alloying elements are added
 Chromium is the alloying element that imparts to stainless steel their corrosion
resistance qualities

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Fig 1.Corrosion Resistance of Stainless steel

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Types Of Stainless Steel

 Austenitic

 Ferritic

 Austenitic- ferritic (duplex)

 Martensitic

Some of the commonly used grades of stainless steel for rebar

applications are type 304,316(austenitic) and 2205(duplex).

The alloy is selected based on mechanical properties and the

expected exposure or corrosivity of the service environment, i.e. the
level of corrosion resistance required.

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Austenitic
It is made by adding nickel (from 8 to 25 percent) and increasing the
chromium level (from 17 to 25 percent). Molybdenum can also be

added (up to 7 percent) to increase the corrosion resistance

Basic properties:
 Excellent corrosion resistance in organic acid, industrial
and
marine environments.
 Excellent weldability (all processes)
Excellent formability, fabricability and ductility
Excellent cleanability, and hygiene characteristics
Good high and excellent low temperature properties (high
toughness at all temperatures)
Non magnetic (if annealed)
Hardenable by cold work only 11
Ferritic
Ferritic stainless steel has properties similar to mild steel but with
the better corrosion resistance. These alloys are somewhat less
ductile than the austenitic types. These are plain chromium stainless
steels with varying chromium content between 12 and 18%, but
with low carbon content

Basic properties:

Moderate to good corrosion resistance increasing with

chromium content
Not hardenable by heat treatment and always used in the
annealed condition
 Magnetic
Weldability is poor
Formability not as good as the austenitic 12
Austenitic-ferritic (Duplex):
Austenitic-ferritic (duplex) duplex stainless steels have a metallurgical
structure that is a combination of both ferritic and austenitic. They have a high
chromium content (from 18 to 26 percent) and a low nickel content (from 4 to 7
percent). Most grades also contain some molybdenum (from 2 to 3 percent)

Basic properties:

High resistance to stress corrosion cracking

Increased resistance to chloride ion attack

Higher tensile and yield strength than austenitic or ferritic

steels

Good weldability and formability 13

Martensitic
Martensitic stainless steel contains mostly 11 to 13% chromium
and is both strong and hard with moderate corrosion resistance.
Martensitic stainless steels were the first stainless steels
commercially developed (as cutlery) and have relatively high
carbon content (0.1 - 1.2%) compared to other stainless steels

Basic properties
Moderate corrosion resistance

Can be hardened by heat treatment and therefore high strength

and hardness levels can be achieved

Poor weldability

Magnetic

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Is Stainless Steel Costly?
UNEXPECTED COST

ADDITIONAL OPERATING COST

REPLACEMENT COST

LOST PRODUCTION COST

MAINTAINANCE COST
INSTALLATION
INSTALLATION COST

INSTALLA
INSTALLATTION COST
MATERIAL COST
MATERIAL COST

STAINLESS STEEL CARBON STEEL

 Initial cost of stainless steel products will definitely be higher.

 However to work out the cost of ownership and usage over the
design life of the structure, say 50 or 80 years, one has to include
the initial cost and add the cost of maintenance, repair,
replacement, downtime and other factors.
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 This method called as the life cycle costing (LCC) analysis, will
show how much the choice of different materials is actually going to
affect the cost of ownership and use of the structure
 Viewed in this manner stainless steel always proves itself to be
the most cost-effective choice over the design life of the structure or
the product
 The end result is always the same stainless steel is cost-effective
to the user

EXAMPLES
 Take for instance the repair cost of Old Thane Creek Bridge.A-5
year life extension after just 10 years of service cost eight times the
original cost (800% increase)
 Partial repair to Janak Sethu Bridge built in 1981 in Delhi cost Rs
32 crore in 1999, whereas the initial cost of the bridge was only Rs 9
crore (250%) increase 16
Actual Life Costing Example-Oland Bridge,Sweden

Fig 4

 On an average, most bridges need a repair between 18-22 years,

at an average cost of the original cost of the bridge itself.

 In the above example, the initial capital cost increase amounts to

4% for Type 304 and 8% for Type 316

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 The increase in overall cost of the project by the introduction of
stainless steel reinforcement bars can vary from 0.5% to 15%
depending on the design.

 Maximum durability is obtained with total substitution of stainless

steel rebar in the structure.

 However, selective substitution is considered as a means of

achieving enhanced durability at minimum increase in initial cost.

 For example, enhanced durability can be achieved by substituting

stainless steel for carbon steel rebar in the parts of the bridge
considered to be at high risk to corrosion while the remainder of the
reinforcement will be normal carbon steel. (Schaffhausen Bridge -
Only half percent increase in initial project cost).
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Advantages
The following benefits of stainless rebar
Corrosion resistance: When embedded in concrete, rebar
made of S31600, for example, shows superior (five to ten times
better) resistance than that of carbon steel. Stainless steel rebar
has been used in several highway overpasses and parapets in
the U.K., Michigan, Oregon, New Jersey, and Ontario; in
concrete structures constructed in aggressive marine
environments; and in the repair and renovation of historic
buildings.
Ease of handling and shipping: Unlike coated rebar, stainless
steel is much easier to work with during shipment and while on
site. Its inherent protective oxide layer is resistant to damage; it
cannot chip, crack or fail. Stainless steel is also easily welded
and can be bent into desired shapes.
Lighter structure (greater strength) 19
 Fire and heat resistance
 Impact resistance
 Environmental friendly
 Durability: In composite structures like RCC bridges, 125 years of
trouble-free service life can be guaranteed.
 Available in many different product forms
 Good strength
 Good weldability for common rebar grades
 Good ductility for common rebar grades (capable of 3D 180E
bends)
 No coatings to chip, crack, deteriorate
 No coatings to damage and repair
 Good mechanical properties for common rebar grades at high and
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low temperatures
Applications
 A host of marine structures such as bridge decks, sidewalks,
ramps, parapets, pilings, barriers, retaining walls, anchoring
systems, parking garages, sea walls, columns, piers, jetties and
moorings
 Anchorages and any kind of joints
 Offshore platforms
 Tunnels, underpasses and subways
 Bridges, viaducts, overpasses
 Cement frameworks with magnetic characteristics
 Frameworks which are prone to breaking up due to frost or
because of low temperatures
 Concrete slabs for drainage in environments with corrosive
agents
 Supports/restoration for statues, monuments, cement, stone and
marble works
 Historic buildings

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A Coastal Replacement Bridge at North Bend, Oregon Has Used
2205 Stainless Steel Rebar Instead of Carbon Steel Rebar for
Critical Structural Elements in a Harsh Marine Environment.
ODOT Expects the New Bridge to Provide Maintenance-free
Service for an Amazing 120 Years. That Is 2.5 Times the Service
Life of the Bridge It Is Replacing!
Replacing

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Nuclear Plant In France: Stainless Steel Has Been Used to Build
Ferroconcrete Drums for Disposal of Radioactive Nuclear Wastes. In
This Application, for Safety Reasons, Is Mandatory the Use Stainless
Steel in Order to Avoid Cracks in the Concrete (Caused by
Reinforcing Bars Corrosion) and Subsequent Waste Leaking

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Stainless Steel Is Also Used in Restoration Works

Colosseum, Rome - Italy

The work involved the partial restoration of the arena floor.
The foundations in roman concrete was reinforced by stainless steel
ribbed bars type AISI 304L in diameters 6, 8, 10, and 14 mm. Total
quantity 3 tonnes.

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Glandstone Bridge, Queenslans, Australia
The Gladstone Bridge Was Built in 1960 and Showed Corrosion of the
Reinforcing Mild Steel on the Deck.
The Maintenance Works Have Seen the Use of 12 mm Diameter Stainless
Steel Ribbed Bars Type 316L Joined With the Original Carbon Steel

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 Conclusions
 The primary intention of this presentation is to create an awareness on the
substantial advantage one can get by using stainless steel as reinforcement in
concrete structures
 Despite the initial cost, there is considerable potential in savings of life cycle
cost, especially infrastructures, which are exposed to corrosive environment
 Best suited material at all temperatures. Also stainless steel are suited for
cryogenic applications
 Available in different grades and hence significant savings can be done
 Also the material is available in different forms, which is more advantageous
 Material is new generation and environmental friendly hence can be very
rightly utilized as a new generation material for all applications

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References
 By K mani and P srinivasan-“service life of RC structures in corrosive environment: A
comparison of carbon steel And stainless steel bars”- indian concrete journal, volume
75,1-12,2001
 By Y sakumoto, T nakazato and A matsuzaki- “properties of stainless steel For building
structures”- ASCE journal Of structural engineering, volume 122,1-6,1996
 Web site references:
A. Use of stainless steel reinforcement bars for concrete structures-by dr. N.C mathur
(president), ramesh R gopal (general manager), nickel development institute & secretary
indian stainless steel development association, 55-A, uday park (ff) khel gaon marg, new
delhi - 49
(published in new building materials & construction world - september 2000)
B. Www.ISSDA.Com-stainless steel assures durability And enhances aesthetics Of
structures-by ramesh R gopal, secretary, ISSDA and general manager of nidi
C. Www.SSINA.Com- stainless steel bridge-new bridge uses stainless steel rebar To last
120 years, CNC west feature article, august  september 2002 vol. XX no. 6 An arnold
publication
D. Www.Outokumpu.Com

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THANK YOU

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