NABED: is Performance of a 60-Year-Old Concrete Pier with Stainless Steel Reinforcement Prono Casrno-Boxcrs, ce 1 ode nvetgactn y Est lds esis, Dep ‘Otapss Troconts DE RINOON, FACE Unive de 2 sca Apenda Centro de Bstuaios do Corrosion Enic Le MORENO, ti “Axpnés Axrosio Tonnes-Acosta ax MiGUEE. MARFINEZ-MADRID, fo Ne ‘Asc Ko» el ‘A60-year-old concrete pier, constructed with stainless steel reinforcing bars (rebar) and exposed to a tropical marine environment, has shown good performance during its service life. This article describes the tests carried out on the pier during this investigation. The tests included visual inspection, chloride content determination, and concrete resistivity as well as electrochemical measurements to the rebar. The authors also discuss durability issues on the pier, based on the results obtained. coma de Yucatn, Facute de bgeneria 0 del Tanspome, Sere IN, RAMBULL-Brige Maintenance dnd Concrete Tectnogy ria de Comunicaciones yEransportes he good condition of a concrete pier in the Por of Progreso de Yucatin, Mexico Figure » ised intesna tional interest. The pier as built from 1937 «0 1951 by a Danish contractor,’ who pre sented the winning design to the Mex can government based on the use of Stm free span concrete he pier dimensions, obtained from a recent survey performed by the Mexican Sec retariat of Communications and Trans portation (SCT), appear in Figuce 2, The pier (1.752 m long and 9.5 m wide) consists of 146 hinged arches 12m centerto-center span and 16m high (Figure 2). Fach arch is supported at the ends by reinforced conerete girders, each resting on two massive cconerete piles. One af the reasons why this design was selected was to elimi nate conventional carbon steel rein forcing bars (sebar) by using massive concrete in the substructure. The Mexican authorities wanted to build this pier having low or no corrosion risk, thus avoiding the severe corre sion problems that had developed in several other marine structures in Mexico, This innovative project ut lized type 304 stainless steel (88) (UNS $3040) for girder reinforcement and, in the long term, for corrosion protec tion, To do so, 220 tons (199.584 kx) of 30-mm-diameter $8, nondeformed bars were used.’ The pier shows no visible sign of deterioration after 60 years of service,even though the structure has received. ‘no maintenance during this period of time, according to port authorities? Using modem techniques (mechani cal, physical, and electrochemical), several actions have been taken 0 verify the actual state of the pier to out ne maintenance actions to extend the pier's service life, A fullpier examina tion, based on the prelim tion discussed in this article, is sched uled in the near future, nary inspec This article presents the results of the preliminary is well as the current ac tions taken as a result of the inspec tion. This preliminary investigation in cluded a visual inspection of the pier substructure and an assessment of chloride penetr: cal parameters on only one girder re inforced with SS rebar. ion and electrochemi: Experimental Procedure Initially, a complete visual inspec tion was performed along the 2-km pier and the wharf substructure, fol lowed by a more detailed inspection The following tests were performed in order to obtain quantitative informa tion on this pier + Concrete: cirbonation front, elec trical resistivity, and chloride pro file * Reinforcement: electrochemical potential (E,_) and apparent corro- sion rate (9. The girder located at the shoreline was selected (0 perform these tests. Figure 3 shows the location of the core extractions and electrochemical mea Conerete cores, 50 mm in diameter, were obtained from each girder’s edge surfaces to test for carbonation depth, chloride content, and concrete poros- In addition, an $8 bar sample was analyzed to determine the chemical composition. Some cores and densi were extracted at specific locations ear areas where the reinforcement was exposed from a previous inspec This allowed investigators to verify the position and condition of the En 320 304 1 464+) a meee Lengel section oheg. SS reinforcement. ‘The total chloride content was estimated from a dry pow. der concrete sample using an acid- digestion extraction, followed bya po- tentiometric titration determination ac cording to welkestablished methods. By and I, Values were obtained using a commercially available linear polarization instrument with a guar ring electrical confinement array. The sensor was placed on top of the longi tudinal $8 bars of girder #9, with one rebar facing the sea (north face), and the other facing inland (south face) Figure 3). In the same manner, resis. vity measurements were performed ing a four poimt Wenner array Results and Discussion VISUAL INSPECTION Of the 146 arches, ~100 were vist ally inspected and few cracks were “observed, Only six arches presented 3 mm-wide cracks. A total of 15 arches presented narrow cracks, with crack widths in the range of 0.1 to 1.0 mm, As the arches were made of massive, nonreinforced concrete, there is no tisk of metal corrosion. A detailed in- spection of the dam: ture was recommended, however. No corrosion duced cracks were observed .e in the near fu the f substructure entire pier and whi Only a few damaged girders at the wharf showed exposed SS bars— probably caused by sh impact— besides the exposed steel observed in girder #9, MATERIALS CHARACTERIZATION The SS was identified as AISI 304 grade (0.08%C, 18%Cr, 8.6%ND by energy dispersion analysis (using a scanning electron microscope) in agreement with a previous investiga (October 2002 MATERIALS PERFORMANCE 51Materials Selection & Design Location of th core extations and electrochemical measurements onthe pier tion The miceosteuctnre was identi fied as austenitic with ASTM grain size No. 8. ‘The fine and coarse aggregate, ob. served from the extracted cores, con sisted of crushed limestone with a coarse aggregate nominal maximum size of 25 mm, The concrete total po. rosity was estimated using the ASTM. (642° standard test method. The val tues ranged from 19 €0 24% mated concrete density was 2.2 gm/ cm’, Based on a petrographic analysis, rom a previous investigation water/cement (w/e) ratio was esti mated to be in the range of 0.50 10 0.70, with a mean value in the range of 0.55 10 0.60. The carbonation depth, measured on three of the extracted concrete The esti- ‘52 MATERIALS PERFORMANCE ceiver 2002 cores, mnged from 010 1.5 mm. These low values, considering the low-qual- ity conerete, n concrete’s high level of chloride con stem from the ‘CONCRETE RESISTIVITY Resistivity measurements showed values ranging from 0.6 to 2.5 Kem in the entire girder surface (Table 1D. This defines a highly aggressive me dium for most metals, Confirming those values in other girders would indicate a h cause the lowest value is similar to the lowest resistivity observed in marine concrete.? These low-resistivity values were expected hecause the reported w/e ratio used in this structure is char acteristic of a low-quality concrete risk of corrosion be B,., AND _q, MEASUREMENTS, The E,,, and J,,, values reported in Table 2 are usually associated with depassi The agreement in the results observed irom both testsis a good indication that the tests were aot affected by transfor: mations of Fe to Fe.’ Usually, the lin cal polarization resistance test cannot be used to evaluate corrosion sates if proximity exists between E.., and the redox potential of another reaction (the results incorporate the effect of all redox processes). In this ease, be cause of the negative corrosion poten tial measured (~-350 mV ys copper/ copper sulfate [Cu/CuSO,] electrode [CSE), the contribution of the Pe/ Fe current density is not possible (-H455 mv ws CSE)?” According (0 a previous report re garding this pier," SS bars were ¢ rectly exposed in the west girder No, 9 because of insuffi ‘concrete cover (<1 em). Becaus portions of reinforcement belong (0 the bended part of end hooks, siress corrosion cracking (SCC) has affected these areas (Figure 4), The SCC was also evaluated! in this investigation, At this time, it isunclear whether SCC was an initial or subsequent event: either the chloride ion caused SCC in the em bedded steel and then the loss of th ‘concrete cover or the steel was firstex TABLET RESISTIVITY MEASUREMENTS IN NO. 9 GIRDER Resistivity kl-em Face North sou Est WesSA oe CORROSION POTENTIALS AND CORROSION RATES IN NO. 9 GIRDER Corrosion Potentials (mV vs CSE) and Corrosion Rates (A/cm? Point East > West 2 Face (ey ae Bae, Nent E a7 eee ee ee ee 1 dost 0015 South Bg A AB ATS 406 HR HHHHHH HL i uz ois Face P, P, P, Pee Pray, PB mE ra -28S =ass 285-287 “268 HE ni 030 Wet &, 2 82 E 4a 4s tt posed (because of the low concrete cover) and then SOC occurred. By com- paring the results from reference (4) with the visual inspection reported here, itis clear that after 3 years the corrosion of the reinforcement has not significantly worsened. Very severe localized corrosion was ‘observed on the top of an SS rebar Io- cated in the east fice, however. This rebar was exposed :ifter the previous in- vestigation (December 1998), and it is located in a vertical position with 3 em of concrete cover. Corrosion was not ‘observed on the bottom of the rebar, where the seawater from the marine breeze tends to accumulate, thereby cre- ‘ating an ideal place for the initiation of In order to verily the validity of the E,., 4nd I, Measurements, the re- searchers Obtained conerete cores from the area above the exposed SS bar. These cores helped to confirm the position of the SS bar inside the girder and the surface condition of the unex- posed metal, Figure 3 shows the loca- ons of the extracted cores. The insert shows. small part of the embedded ss bar surface condition exposed after concrete core drilling. A few rusty spots were observed and identified as pitting, (CHLORIDE CONTENT ‘The tropical marine environment of the northern Yucatan Peninsula has been characterized in terms of its at- ‘mospheric aggressiveness as a grade 5 ‘on the International Organization for Standardization (ISO) scale."""* This designation represents the most ag gressive marine environment on this scale. Asa result of the aggressiveness and the high porosity of the concrete, high chloride concentrations at the rebar level were expected. Figure 5 shows the chloride profile concentrations obtained from two dif- ferent cores, one extracted from the west face and the other from the south, face. The chloride concentrations at the rebae depth obtained in this inves. tigation are in agreement with those obtained in the previous survey.) The ‘maximum chloride concentration ob- 0306 363 0351 tained was somewhat above the maxi- ‘mum soluble chloride concentration in te should, solutions. This maximum not be considered impos achieve if one considers that the con- crete cores were obtained ahove the ‘waterline and thus were not saturated The chloride extraction method was used to obtain total chlorides, and the dey concrete mass was not corrected by watersfilled porosity that will de- crease the concentration by ~10%. ‘The chloride threshold for AISI 304 ‘was estimated to be between 0.7 and 1 wil of conerete.!*" According to the chloride profiles obtained for the evalt- ated girder (Figure 5), the chloride con- tent measured at the rebar depth (=1.2 ‘ws of dry concrete) is above the chlo- tide threshold reported for this type of rebar. However, t higher chloride threshold for AISI 316 and AISI316 clad bars has been reported elsewhere.” ‘The previous results regarding E,,,. Togs and chloride content at the bar depth confirm that the $8 rebar at tuirder No. 9is in the process of active corrosion, This situation demands fur ‘October 2002 MATERIALS PERFORMANCE 53Matertals Selection & Design presented to the SCT government au- thorities, The program includes the selection of six bents to pesform tests on the piles, girders, and arches. Fur ture testing will include the determi ation of chloride profiles, carbon ation front, concsere resistivity, | E.,,. total and effective conceete po rosity, and petrographic analysis. ‘The results of these ests would al low the researchers to determine, with a higher degree of confidence, the chemical and physical character istics of the piee’s materials. Conse quently, it would enable tem to pre dict the residual service life of the pier ind to outline an effective mainte- nance program, Conclusions A preliminary insps z Progreso pier in Yucétan, Mexico, provided enough quantitative infor Imation to suspect that the 88 bars 05 che ziniersare exposed toa high chloride concentration that Is posst bly causing their depassivation | ‘Adetailed inspection progrim has Rebar position | n recommended to Mexican gov ae rm LUDOves nee this hypothesis Acknowledgments. The authors acknowledge partial support from Consejo Nacional de Giencia y Tecnologia (GONAGYT) Threshold for 85° (Mexico City, Mexico), Fondo Nacional de Ciencia, Teno logia Innovacion CFONACTT) (Caracas, Venenucla), Centro de Investigacion y de Istudios Avan ig 22408 ccanvestavy del ten Unidad : Mérida (Mérida, Mexico), Instituto Penetration Depth (mm) Girder No.9, where most ofthe tests were perfrmed, SCC occured on rebar exposed a this rer. sion of the “+ West face — South face 2 a Chloride Concentration Gt of Concrots) a ° Mexicano del Transporte, and FIVADY for this investigation, The Che oncetaton ples in er No authors are indebted to C, Andrade and A. Sagiés for helpful discus sions and to M. Balancin and theranalysisto corroborate—by means «STRATEGIES FOR FUTURE ——_G._ Diaz for performing the tests of a more extensive and systematic DETAILED INSPECTION The opinions and findings are study—if other girders beyond the Asaresuftofthe preliminary inspec- those of the authors and nor neces shoreline are also experiencing corro- tions already performed on this pier,a sarily those of the supporting sion degradation." detailed inspection progrim has been organizations. BA MATERIALS PERFORMANCE Oetner 2002' We'd be References DAO CASTRO BORGER emer a eee! §6terrible ‘Mexico. He specializes in concrete durabily including inspection. evaluaton, diognsis, sence creams ears (eeeetiiaeeneeneacaer | MMM DELLA Socieemsaums serge te : guests. insect tc ie tan teat QLADIS TROCONIS DE RINCON, FNACE. is Doctor of the Corosion Study Center, The Univesy of Zula, A, Goji, Focuty of Engineering, Apdo, 10482, Maracaibo, Zul, West Conshobichen, PA ASTM. 1997) Venezuela Se has 28 years of experince inthe First to arrive. Last to lea Foon eee nection, e0RS6 fld. Her essarch interests incl valent sel bhai on nee €8ROSi6n andl crosion contol in reinforced crete Siructues (in pani), DURA Repor cnctee structs, metalic coatings, and atmospheric corosion. Sho isthe nteatonal easel k camaes ‘Comaen ete tein C00Rtnator of the beroamerican project Sine Prpeaieran pe aba ncaa mss MOREA TORES ACO ert A phaamonk Nol 2 Common, 7 cuton OME Einar at thereto Mecano del Tansore_| (OM, Kn 124000 Cantera Queretaro Galindo, ‘Sarfanda, Queer, 76700, Manica He is vnsinnace, Chaiman othe Mescan Secon ofthe CYTED- nian ‘Buraconberoamerican- Network Project He wos | inthe areas of construction mateals and cubiy of coneete suctres He has» PRO. cl cane €89ieerng fom the Uiversty of South Florida nae Seen Untick adh, A hea was the ratplae recon ofthe Mars KS, U oon tnimcomcr Canny The tance, Fonts Award given st the CORROSION96 si of Heth Coln, 2007 1.36 ‘Student Poster Session. Hei a S-year member of TH. Mikomdo. 1 Veleva,sCorasiny Category NACE ERIC VAN MORENO is Press Uniersidod Autonoma de Yuratn, A ndustins No Containantes s/n x ilo Pereico Nort, Mérid,Vucati, Mexico. He has 10 years of isis esearch experience nthe aes of lacrochersial ve evmisox echnical brochure, “aRaHNox ‘@Aarng and corsion of reinforcing tel n ‘concrete. He has an MS. and PRO. fom the ey Virmani. “Stainless Stee! Rew igen you the opportunity to browse the seen Canc created fe rclvssy ges, ASGER KNUDSEN is Project Director at Senet eee SEERA 279 reoistration questions answered. Denmark ane abroad in inspection and rehabit ton of coneret and ste structures. The _assigamonts have involved inpecton, testing. reporting. and preparing rehabilitation projets and seeceatione MIGUEL MARTINEZ MADAID is a Researcher at UNAM, Certro de Fics Apoae y Teehroogia ‘Avanzada, Campus Juri, Jurgulla,Sentogo de Queret, Qro 76230, Meco. He develops This article ts based on CORROSION/ technologies tat can be spp in Mexico's 2002 paper mo. 207, presented in Denver, mal and clinducr, He's 22 yeor member of Colorado NACE. IP October 2002 MATERIALS PERFORMANCE 55