Bridges Middle East - Qatar

Doha, 12th April 2010

Selection of stainless steel for the

durability of bridges in highly aggressive
marine environments
Luca Bertolini
Politecnico di Milano - Department CMIC
luca.bertolini@polimi.it

Degradation of reinforced concrete

H2O
O2
Concrete CO2
Reinforced SO4=
concrete Cl-
Steel rebars acids
temperature
loads

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Chloride induced corrosion

Chlorides
Time = t1

Clcr
Depth
x

H 2O

Cl-

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Chloride induced corrosion

Chlorides

Time = t2

Clcr
Depth
x

H 2O

Cl-

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Chloride induced corrosion

Chlorides
Time = t3 = ti

Corrosion initiation
Cl(x,ti) = Clcr Clcr
Depth
x

H 2O

Cl-

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Chloride induced corrosion - Exposure conditions

Marine structure
+ high temperature and salinity

Atmospheric
Chloride

1) wet/dry cycles
2) oxygen availability Tidal/splash/spray

Submerged

Clcr

Depth
cover thickness

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Chloride induced corrosion - Prevention (Splash - DSL>100 years)

1) Delay chloride penetration

→ concrete composition
→ surface treatments
Chloride

2) Increase concrete cover thickness

3) Increase the chloride threshold
→ preventative measures
1
4) Avoid metallic corrosion
→ epoxy coated or FRP bars
3
Clcr

Depth
cover thickness 2

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Chloride induced corrosion - Prevention (Splash - DSL>100 years)

Reinforcing bars with improved corrosion resistance:

- stainless steel 3) Increase the chloride threshold
→ preventative measures

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Stainless steel bars
Austenitic

Approximate chemical composition (% by mass) Designation

Other
Cr Ni Mo AISI EN
elements
17.5-19.5 8-10 - - 304L 1.4307
16.5-18.5 10-13 2-2.5 - 316L 1.4404

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Stainless steel bars

Austenitic
Duplex austeno-ferritic
Approximate chemical composition (% by mass) Designation
Other
Cr Ni Mo AISI EN
elements
17.5-19.5 8-10 - - 304L 1.4307
16.5-18.5 10-13 2-2.5 - 316L 1.4404
21-23 4.5-6.5 2.5-3.5 N 318 1.4462
22-24 3.5-5.5 0.1-0.6 N - 1.4362
21-22 1.4-1.7 0.1-0.8 Mn, N - 1.4162

The corrosion resistance of stainless steels in concrete depends on:

- the type of stainless steel (composition, microstructure, ...)
- environmental conditions (temperature, moisture, ...)
- the surface finishing (mill scale, welding oxides, ...)

Ref.: L. Bertolini et Al., Corrosion of steel in concrete, Wiley, 2004

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Stainless steel bars
Progreso pier (Mexico)
Pier built in 1969 Pier built in 1940
(black steel) (AISI 302)

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Chloride induced corrosion - Prevention (Splash - DSL>100 years)

3) Increase the chloride threshold

→ preventative measures

Reinforcing bars with improved corrosion resistance:

- stainless steel

- galvanized steel
- others (e.g. MMFX)

Corrosion inhibitors (mixed-in or migrating)

Cathodic prevention

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Cathodic prevention

CPre

Clcr Clcr

Refs.: P.Pedeferri, Constr. Build. Mat, 1996 - EN 12696, 2000

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Cathodic prevention

Installation (during construction)

Cables

Power
Reference supply
electrode
Monitoring
System

Anode: Activated
Titanium MMO
Remote
control

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Cathodic prevention

Operation (throughout service life)

Continuous monitoring and
inspection

Maintenance
- Reference electrodes
- Cables and connections
- Feeder / datalogger

Durability?

Durability?
Durability?
L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Cathodic prevention

Operation (throughout service life)

Continuous monitoring and
inspection

Maintenance
Durability?
- Reference electrodes
- Cables and connections
- Feeder / datalogger
- Anode
Durability?

Durability?
Durability?
L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Design for durability

Durability Design service life Performance

1) Deemed to satisfy rules

2) Performance based approaches
• long service life (>50 years),
• high environmental aggressiveness (e.g. splash zone
of marine structures, joints, ...)
• reduce accessibility for inspection,
• high direct or indirect costs of maintenance,
• use of different materials (blended cements,
corrosion resistant reinforcement, corrosion
inhibitors, ...)

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Probabilistic approach

FIB, "Model code for service life design", 2006

Pf = P {ccr − c ( x, t ) < 0} < Po

C(x,t)
(% mass cement)
Chloride

Ccr Ccr

Pf
C(x,0)
t1 ts* Time
Design Service Life

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Probabilistic approach - An example
Marine environment - Splash zone
Design Service Life = 120 years,
Impervious concrete: DRCM < 1.5.10-12 m2/s (e.g. 70%GGBS, a/c < 0.4, good curing, ...)

50
45 Highest
40
35
Average
Temperature (°C)

30
25
20
15
10
5 Qatar-Bahrain
0

November

December
June
January

February

March

May
April

August

September

October
July

Ref.: Concrete Society, 2008

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Probabilistic approach - An example

Marine environment - Splash zone
Design Service Life = 120 years,
Impervious concrete: DRCM < 1.5.10-12 m2/s (e.g. 70%GGBS, a/c < 0.4, good curing, ...)
10
Black steel
8
Probability (%)

0
0 1 2 3 4 5 6 7 8 9 10
Chloride threshold (% mass of binder)

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Probabilistic approach - An example
Marine environment - Splash zone
Design Service Life = 120 years,
Impervious concrete: DRCM < 1.5.10-12 m2/s (e.g. 70%GGBS, a/c < 0.4, good curing, ...)

8
7

Probability of failure (%)

6
5
Safety index β

4 0.01
3
30°C
1
2 β = 1.29, Pf = 10% 35°C
40°C
10
1 45°C
0 50
-1
25 50 75 100 125 150 175
Mean concrete cover (mm)
L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Probabilistic approach - Corrosion resistant rebars

Marine environment - Splash zone
Design Service Life = 120 years,
Impervious concrete: DRCM < 1.5.10-12 m2/s (e.g. 70%GGBS, a/c < 0.4, good curing, ...)
10 Black steel
T = 35°C Galvanised steel
8 Microcomposite (MMFX)
Probability (%)

21-01 (1.4162)
6 23-04 (1.4362)
304L (1.4307)
4 316L (1.4404)
22-05 (1.4462)

0
0 1 2 3 4 5 6 7 8 9 10
Chloride threshold (% mass of binder)

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Probabilistic approach - Corrosion resistant rebars
Marine environment - Splash zone
Design Service Life = 120 years,
Impervious concrete: DRCM < 1.5.10-12 m2/s (e.g. 70%GGBS, a/c < 0.4, good curing, ...)

8
T = 35°C
7 1.4462
1.4404

Probability of failure (%)

6
1.4307
5 1.4362
Safety index β

4 1.4162
0.01
MMFX
3 Galv.St.

Black
1
2
steel
10
1 β = 1.29
0 50
-1
25 50 75 100 125 150 175
Mean concrete cover (mm)
L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Probabilistic approach - Corrosion resistant rebars

Marine environment - Splash zone
Design Service Life = 120 years,
Impervious concrete: DRCM < 1.5.10-12 m2/s (e.g. 70%GGBS, a/c < 0.4, good curing, ...)
175
beta = 1.29 (Pf = 10%)
Concrete cover thickness (mm)

Black
150 steel

125 Galv.St.
MMFX
100
1.4162

75 1.4362
1.4307
50 1.4404
1.4462

25
25 30 35 40 45 50
Temperature (°C)
L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Combined use of stainless steel and black steel rebars
Passive carbon steel has a corrosion potential similar to the corrosion
potential of passive stainless steel No galvanic couple

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

Combined use of stainless steel and black steel rebars

Passive carbon steel has a corrosion potential similar to the corrosion
potential of passive stainless steel No galvanic couple
Corrosion may only initiate if the chloride threshold is reached (i.e. wrong
design) No galvanic action of stainless steel on carbon steel

20°C
14
95-98%R.H.
Macrocell c. d. (mA/m2)

12

10

0
Black steel AISI 316L AISI 316L
0%Cl- 0% Cl- 3% Cl-
Refs.: L.Bertolini et Al., FHWA, 1998 - Concrete Society, T.R. No. 51, 1998
L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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 Concluding remarks

If long service lives (>100 years) are required for RC structures

in highly aggressive marine environments, protection of steel in
the splash zone cannot be provided simply by a "thick" and
"dense" concrete cover. Preventative measures that increase
Clcr are also necessary.
Cathodic prevention could maintain passive conditions on black
steel. Nevertheless, it requires continuous monitoring in order
to guarantee that protection criteria are fulfilled throughout
the structure and it requires periodic maintenance and replace-
ment of its hardware.
The use of rebars made of a suitable grade of stainless steel can
provide a maintenance-free solution with high levels of reliabi-
lity. Selection of the grade of stainless steel has to take into
account the exposure conditions and be part of the design
procedure.

L.Bertolini - Selection of SS for bridges in highly aggressive marine environments

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