NEW GENERATION STAINLESS STEEL REINFORCING BARS FOR CONCRETE STRUCTURES

CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. Introduction Causes of corrosion Stainless steel Types of stainless steel Cost of stainless steel Applications Conclusion References

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 are starting to show 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
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What Causes 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 products-oxides-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 Rebars.

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

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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

Fig 1.Corrosion Resistance of Stainless steel

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.

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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:
and

Excellent corrosion resistance in organic acid, industrial 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) Hardenable by cold work only
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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
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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
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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
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Is Stainless Steel Costly?

UNEXPECTED COST
ADDITIONAL OPERATING COST REPLACEMENT COST LOST PRODUCTION COST

MAINTAINANCE COST
INSTALLATION COST INSTALLATTION COST MATERIAL COST MATERIAL COST STAINLESS STEEL CARBON 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.
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 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 cost-effective 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
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Actual Life Costing Example-Oland Bridge,Sweden

Fig 4

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
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 The increase in overall cost of the project by the introduction of

stainless steel reinforcement bars can vary from 0.5% to 15%

depending on the design. Maximum durability is obtained with total substitution of stainless steel rebar in the structure. However, selective substitution is considered as a means of achieving enhanced durability at minimum increase in initial cost. For example, enhanced durability can be achieved by substituting stainless steel for carbon steel rebar in the parts of the bridge

considered to be at high risk to corrosion while the remainder of the

reinforcement will be normal carbon steel. (Schaffhausen Bridge Only half percent increase in initial project cost).
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Advantages
The following benefits 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)

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 Fire and heat resistance Impact resistance Environmental 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 Good mechanical properties for common rebar grades at high and low temperatures
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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

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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!

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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 Subsequent Waste Leaking

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Stainless Steel Is Also Used in Restoration Works

Colosseum, Rome - Italy The work involved the partial restoration of the arena floor. The foundations in roman concrete was reinforced by stainless steel ribbed bars type AISI 304L in diameters 6, 8, 10, and 14 mm. Total quantity 3 tonnes.

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Glandstone Bridge, Queenslans, Australia The Gladstone Bridge Was Built in 1960 and Showed Corrosion of the Reinforcing Mild Steel on the Deck. The Maintenance Works Have Seen the Use of 12 mm Diameter Stainless Steel Ribbed Bars Type 316L Joined With the Original Carbon Steel

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Conclusions
The primary intention of this presentation 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
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References
By K mani and P srinivasan-service life of RC structures in corrosive environment: A comparison of carbon steel And stainless steel bars- indian concrete journal, volume 75,1-12,2001 By Y sakumoto, T nakazato and A matsuzaki- properties of stainless steel For building structures- ASCE journal Of structural engineering, volume 122,16,1996 Web site references:

A. Use of stainless steel reinforcement bars for concrete structures-by dr. N.C mathur (president), ramesh R gopal (general manager), nickel development institute & secretary indian stainless steel development association, 55-A, uday park (ff) khel gaon marg, new delhi 49 (published in new building materials & construction world - september 2000) B. Www.ISSDA.Com-stainless steel assures durability And enhances aesthetics Of structures-by ramesh R gopal, secretary, ISSDA and general manager of nidi
C. Www.SSINA.Com- stainless steel bridge-new bridge uses stainless steel rebar To last 120 years, CNC west feature article, august september 2002 vol. XX no. 6 An arnold publication

D. Www.Outokumpu.Com
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THANK YOU

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