NEW GENERATION STAINLESS STEEL REINFORCING BARS FOR CONCRETE STRUCTURES

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 start showing 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.

What is 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 productsoxides-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

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

Several Methods Are Currently Employed in an Attempt to Reduce the Corrosion of Carbon Steel Rebar's.

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

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

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.

 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). Harden able by cold work only.

 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

 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

 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

Properties Of Stainless Steel

Grade UNS No. S43000 S42000 S30400 S30403 S31600 S31603 S31803 S32205 FAMILY Crc Nic Moc Nc C (MAX) Yield Strength Mpa (min)b 205 1480 205 170 205 170 450 Tensile Strength Mpa (min)b 450 1720 515 485 515 485 620 Elong % (min)b 22 8 40 40 40 40 25

430 420 304 304L 316 316L 2205

Ferritic Martensitic Austenitic Austenitic Austenitic Austenitic Duplex

17 13 18 18 17 17 22 9 9 11 11 5 2.1 2.1 3 0.15

0.12 0.15 0.08 0.03 0.08 0.03 0.03

b c

- Annealed condition except for grades 420 - Typical values

Fig 2 Stress-Strain Curve

Is Stainless Steel Costly?

Unexpected Cost

Additional Operation Cost

Replacement Cost Lost Production Cost Maintenance Cost Installation Cost Material Cost Installation Cost Material Cost CARBON STEEL

STAINLESS 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.

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 costeffective 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

Actual Life Costing Example-Oland Bridge,Sweden

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

UK Midlands Link Viaduct

Built in 1972 at a cost of 28 million, evidence of corrosion became apparent after two years of operation. By 1989, 45 million had been spent on repair. By 2010 it is estimated that a further 120 million will be spent on repair. Estimated first cost of installing stainless steel reinforcement in critical locations -- 3.4 million (i.e. a 12% increase in the initial cost of the via duct). The total cost of repair of the carbon steel reinforcement till the year 2010

would be 45 plus a further 120 million = 165 million or nearly six times
the original cost of building the viaduct. For a 40-year service life of the viaduct, the price to be paid for not using stainless steel rebar is indeed exorbitant.

Marine Pier in Progresso, Mexico

 The Marine Pier in Progresso, Yucatan (Mexico), was built in 1937-1941. A detailed account of the history and remarkable performance of this pier has been provided by Torben Skovsgaard (ARMINOX) and Asger Knudsen (RAMBOLL) in the August/September 1999 issue of Concrete Engineering International.

2.1 km long pier was constructed by a Danish contractor. Stainless reinforcement (Type 304) was incorporated in view of the severely corrosive exposure conditions. Pier still performs very well, the company reports with almost no sign of deterioration, whereas an adjacent pier made of carbon steel rebar about 30 years ago has virtually disappeared. They estimate the remaining service lifetime to be at least 20 to 30 years, even without any significant routing maintenance activities.

Advantages 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) Economical cost (life cycle cost analysis)

 Fire and heat resistance. Impact resistance. Environmentally 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.

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

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!

New Haynes Inlet Slough Bridge Completed State of the New Haynes Inlet Slough Bridge From North Bank of the Inlet, With Retired Timber Trestle Bridge at Right and Contractor's Partially Dismantled Work bridge in Left Background.

More Than 75 Tons of Type 316LN Stainless Rebar Were Used for the Brush Creek Highway Bridge in Oregon (1998)

165 Tons of 2205 (Duplex) Stainless Rebar Were Supplied for the New Ramp of the Garden State Parkway in New Jersey (1998).

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 Subsequently Waste Leaking.

Stainless Steel Reinforcement Has Been Used in Order to Minimize Future Maintenance Work of the Buildings. The Guildhall Yard East Project in London, England (1996) One of the Most Famous Historic Buildings in the Centre of the City of London, Utilized Over 140 Tons of Type 304 Rebar. Although the New Structures Will Not Be Exposed to De-icing Salts or a Marine Environment, the Design Engineers Were Looking for a Very Long Design Life, in Keeping With the Famous Historic Buildings on the Site

Rocco Church, Dolo, Venezia - Italy The Work of Restoration Was Realized Employing Stainless Steel As the Wall Tie for the Supporting Structure.

Conclusions
The primary intention of this paper 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.

References
Service Life Of RC Structures In Corrosive Environment: A Comparison of Carbon Steel And Stainless Steel Bars- By K. Mani and P. Srinivasan- Indian Concrete Journal, Volume 75,1-12,2001 Properties Of Stainless Steel For Building Structures By Y Sakumoto, T Nakazato and A Matsuzaki - ASCE Journal Of Structural Engineering, Volume 122,1-6,1996 Web site references:

A. www.issda.com- Stainless Steel Assures Durability And Enhances Aesthetics Of Structures- By Ramesh R Gopal, secretary, ISSDA.
B. www.ssina.com- Stainless Steel Bridge - New Bridge Uses Stainless Steel Rebar To last 120 years, CNC West Feature Article, September 2002 Vol. XX no. 6 An Arnold publication C. www.outokumpu.com