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Stainless Steel Reinforcement as a Replacement for Epoxy Coated Steel in Bridge Decks
ODOT-OkTC
Transportation Research Day
Oklahoma City, OKOctober 12, 2013
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Outline
Objectives
Reinforcement
Test methods and Results
Life expectancy and Cost-effectiveness
Conclusions and Recommendations
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Determine the corrosion resistance of 2304 duplex stainless steel reinforcement and NX-SCR™ stainless steel clad bars compared to conventional and epoxy-coated reinforcement in reinforced concrete bridge decks
Estimate the life expectancy and cost effectiveness of 2304 duplex stainless steel, NX-SCR™ stainless steel clad reinforcement, epoxy-coated reinforcement, and mild steel reinforcement in bridge decks in Oklahoma
Objectives
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Reinforcement
Conv.
ECR
2304
SS Clad
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2304
Pickled a second time
As delivered
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Test Methods
Rapid Macrocell test
Southern Exposure test
Cracked Beam test
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Chloride Induced Corrosion
Two phase process:
Phase I – initiation– Time to reach the
critical chloride corrosion threshold
Phase II – corrosion– Corrosion products
build up around reinforcement
Time
Co
rro
sio
n L
oss
Phase I Phase II
Cracking of Concrete
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Measurements and observations
Voltage drop to measure corrosion rateCorrosion potentialMat-to-mat resistanceLinear Polarization to measure microcell and macrocell corrosionCl– content at corrosion initiationCracking and staining of concreteCorrosion on bars following testsEvaluate disbondment of epoxy coating
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Bench-Scale Tests
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Southern Exposure Test
10 ohm
Terminal Box
Voltmeter
15% NaCl solution
12.0 in.
2.25 in.2.5 in.2.5 in.2.5 in.2.25 in.
1.0 in.
1.0 in.
7.0 in.
V
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Cracked Beam Test
VVoltmeter
Terminal Box
10 ohm
6.0 in.
1.0 in.
1.0 in.
7.0 in.
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All bars – Southern Exposure
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Corrosion resistant bars – Southern Exposure, different scale
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Critical Chloride Corrosion Threshold
Reinforcement No. of Samples
Avg. Initiation
Age(weeks)
Avg. Chloride Content(lb/yd3)
Conventional 34 12.5 1.78
Conv./2304 18 8.0 1.76
Conv./SSClad 26 9.3 1.59
ECR 36 16.5 4.59
SSClad-4h 54 26.7 7.62
SSClad -- -- --
2304 35 99.8 20.5
2304/Conv. 14 75.0 20.5
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All bars – Cracked Beam
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Corrosion resistant bars – Cracked Beam, different scale
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2304– Cracked Beam
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2304 (pickled a second time) – Cracked beam
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SS Clad– Cracked Beam
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Cracked beams
Conv. ECR 2304 SS clad
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Comparisons based on:
150 ft span, 42 ft width, 8 in. deck
75 and 100-year economic lives
ODOT costs
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Time to first repair (years)2 ½-in. cover
SteelDesignation Initiation
Initiation to
Cracking
Cracking to Repair
First Repair
Conventional 2.1 7 10 19
ECR 8.4 35 10 53
2304 44 26 10 80
2304-p -- -- 10 > 100
SSClad -- -- 10 > 100
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Costs per yd2 Present worth for 2% discount rate
SteelDesignation
InitialCost
Total costs
75 years 100 years
Conventional $163 $1048 $1265
ECR $198 $422 $422
2304 $275 $275 $423
2304-p $275 $275 $275
SSClad $240 $240 $240
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Conclusions and Recommendations
Corrosion resistant steels, even when damaged, provide significant advantages over conventional reinforcement
Lack of proper pickling reduces corrosion resistance of stainless steel
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Conclusions and Recommendations
Some problems with NX-SCRTM
stainless steel clad reinforcement – the bars are not currently available
Stainless steel reinforcement should be pickled to a bright or uniformly light surface to ensure proper performance
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The University of Kansas
David Darwin, Ph.D., P.E.
Deane E. Ackers Distinguished Professor and ChairDept. of Civil, Environmental & Architectural
Engineering2150 Learned HallLawrence, Kansas, 66045-7609(785) 864-3827 Fax: (785) 864-5631