Weathering Steel

9/14/2011
STEEL BRIDGE FORUM

Raleigh, NC
September 14, 2011
Weathering Steel
The Other Corrosion Protection System
Bill McEleney
Director, National Steel Bridge Alliance
High Strength Low Alloy Steel
High strength - low alloy steel
ASTM A709 - Grades 50W, HPS 50W,

HPS 70W, & HPS 100W
Expect 4 times the corrosion resistance of
carbon steel
Forms tight oxide coating (patina)
9/14/2011
Protective Patina
Weathering Steel
Patina is a thin layer of dense corrosion

b
by-products
d t th
thatt acts
t as a skin
ki to
t protect
t t
against further corrosion.
In use in United States since 1933.
Developed for coal hopper cars to combat
the corrosive effects of sulfur on steel
steel.
New High Performance Steel (HPS) has
improved weathering characteristics.
9/14/2011
Simple, Low Maintenance Bridge
Use of Weathering Steel
BENEFITS
CAUTIONS
Not appropriate in foggy,

coastal regions
Not for use in tunnel-like
conditions where deicing
salts are used
Evaluation
E l ti needed
d d iin
heavy industrial areas
(corrosive chemicals)
Lower Fab Cost

Shorter Fab Time
No Field Painting
Natural Appearance
Minimal Maintenance
Lower Life Cycle Cost
9/14/2011
Uncoated vs. Coated
Use of weathering steel is growing due to:

Reduced cost for blast cleaning, edge
grinding and surface preparation
Avoided cost of first coating systems
Ti
Time in
i the
th fabrication
f b i ti process tto allow
ll
curing between coats
Reduced maintenance costs; traffic
impact
Cost Studies
FIRST COST SAVINGS:

10 TO 18%
LIFE CYCLE SAVINGS:
YES - ???
9/14/2011
Relative First Costs
Material costs 3 - 4 cents/pound more

But, painting costs significantly higher
12 20 cents/pound
Net costs favors Weathering Steel
Lewisburg, PA
9/14/2011
Example Lewisburg, PA
1223 bridge length (886 tons total)

Material extra (@ $.03): $ 53,160
Painting cost avoided (3 coats): $ 270,674
Net 1st Cost Savings: $ 217,514
Life Cycle Cost Savings (est
(est.):
): $ 1
1.5
5M
Design Considerations
SITE EVALUATION
Environmental / Climatic
Site Configuration
FHWA Technical Advisory T 5140.22
9/14/2011
Good Site for A588
Adequate Clearance Over Water
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Avoid Tunnel-Like Conditions
SITE EVALUATION
DETAILS DRAINAGE CONTROL
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Jointless Bridge Detail for Drainage
Jointless Bridge
536 feet continuous
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Expansion Dam Drain Trough
Protect Steel Beneath Joints
10
9/14/2011
Weathering Steel
SITE EVALUATION
DETAILS STAINING
11
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Wrap For Stain Control
Drip Pan For Stain Control
12
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Pier Design For Stain Control
Pier Design For Stain Control
13
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Substructure Coating for Stain

Control
Substructure Material for

Stain Control
14
9/14/2011
Substructure Material for

Stain Control
Drip Bars For Stain Control
15
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Drip Bar Detail For Stain Control
SITE EVALUATION
DETAILS STAINING
DETAILS SURFACE PREPARATION
not in FHWA Technical Advisory T 5140.22
16
9/14/2011
Blast (SP-6) For Aesthetic Patina
Blast Fascia Only
17
9/14/2011
Maintenance Actions
Implement procedures to detect and minimize

corrosion
Control roadway drainage
Regularly remove all dirt debris, etc that trap
moisture
R
Regularly
l l remove vegetation
t ti which
hi h prevents
t
natural drying
Maintain covers and screens over access holes
Weathering Steel
18
9/14/2011
Thats Nice, But
g steel doesnt
.. what about when weathering
work?
weathering steel issue or other?
field painting of weathering steel
FHWA Report Maintenance Coating of
W th i St
Weathering
Steel;
l FHWA
FHWA-RD-91-087,
RD 91 087 M
March
h 92
Weathering Steel
A proven, effective corrosion control

system
t
Specific site conditions
Cost effective
Low maintenance
19
9/14/2011
STEEL BRIDGE FORUM

Raleigh, NC
September 14, 2011
QUESTIONS ??
Bill McEleney
In Florida?
SunCoast Parkway - 1999

3 overpasses
Guardrail
Light poles
Less than 10 miles from Gulf of Mexico
20
9/14/2011
Van Dyke over SunCoast
21
9/14/2011
22
9/14/2011
23
9/14/2011
24
9/14/2011
Caldwell over SunCoast
25
9/14/2011
W. Bowman over SunCoast
26
9/14/2011
W. Bowman Over SunCoast
27
9/14/2011
STEEL BRIDGE FORUM

Raleigh, NC
September 14, 2011
QUESTIONS ??
Bill McEleney
28

Weathering Steel

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9/14/2011

STEEL BRIDGE FORUM

High Strength Low Alloy Steel

High strength - low alloy steel

ASTM A709 - Grades 50W, HPS 50W,

Patina is a thin layer of dense corrosion

Simple, Low Maintenance Bridge

Use of Weathering Steel

Not appropriate in foggy,

Lower Fab Cost

Uncoated vs. Coated

Use of weathering steel is growing due to:

FIRST COST SAVINGS:

Relative First Costs

Material costs 3 - 4 cents/pound more

Net costs favors Weathering Steel

1223 bridge length (886 tons total)

FHWA Technical Advisory T 5140.22

Good Site for A588

Adequate Clearance Over Water

Avoid Tunnel-Like Conditions

FHWA Technical Advisory T 5140.22

Jointless Bridge Detail for Drainage

536 feet continuous

Expansion Dam Drain Trough

Protect Steel Beneath Joints

FHWA Technical Advisory T 5140.22

Wrap For Stain Control

Drip Pan For Stain Control

Pier Design For Stain Control

Pier Design For Stain Control

Substructure Coating for Stain

Substructure Material for

Substructure Material for

Drip Bars For Stain Control

Drip Bar Detail For Stain Control

not in FHWA Technical Advisory T 5140.22

Blast (SP-6) For Aesthetic Patina

Blast Fascia Only

Implement procedures to detect and minimize

Thats Nice, But

A proven, effective corrosion control

STEEL BRIDGE FORUM

SunCoast Parkway - 1999

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Van Dyke over SunCoast

Caldwell over SunCoast

W. Bowman over SunCoast

W. Bowman Over SunCoast

STEEL BRIDGE FORUM

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