Stainless Steel Bars

Stainless Steel Bars

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Background of stainless steel bars

Reinforcement corrosion in concrete due to chloride ingress or carbonation is most serious problem to reduce durability of concrete structures in Japan. Countermeasure to reinforcement corrosion:
low W/C concrete concrete admixtures thick concrete cover surface protection epoxy-coated bars FRP reinforcement electrochemical corrosion control method

Stainless Steel Bars

reinforcement corrosion

JIS for Stainless steel bars for concrete reinforcement was established in 2008.

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epoxy-coated bars

Type of stainless steel

Stainless Steel Bars

SUS304 (18%Cr-8%Ni, ASTM:A276 304)

Basic steel alloy most widely used as stainless steel.

SUS316 (16%Cr-10%Ni-2%Mo, ASTM:A276 316)

More corrosion-resistant steel alloy obtained by adding molybdenum to SUS304.

SUS410L (12%Cr-LowC, ASTM:A276 410L)

Chromium stainless steel with a controlled alloy content. Corrosion-resistance: SUS316 > SUS304 > SUS410
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Tests on corrosion-resistance of stainless steel bars

Bare steel in solution Embedded in mortar Embedded in concrete Exposed to actual corrosive environment Touching with different kind of metal etc.
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Stainless Steel Bars

Corrosion test in solution

Potentiostat Reference Electrode

Stainless Steel Bars

3 types of solutions No.1: pH9.1-9.7 Solution No.2: pH11.9-12.6 No.3: pH13.2-13.4 Specimen

Thermostatic Tank (40deg) Counter electrode

Duration of test48hours corrosion criterion 0.5mA/cm2

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Stainless Steel Bars

Results of corrosion test in solution

pH 12.6

corroded in 0.5% Cl-

not corroded in 0%

corroded in 0.5% Cl-

not corroded in 0% Cl-

conventional carbon steel

stainless steel: SUS410L

corroded in 4.0% Cl-

not corroded in 3.0% Cl-

corroded in 8.5% Cl-

not corroded in 8.0% Cl-

stainless steel: SUS304

stainless steel: SUS316

Corrosion criterion of chloride concentration in solution

16 14
corrosion criteria(%)

Stainless Steel Bars

12 10 8 6 4 2 0 8 9

Carbon steel SUS410L SUS304 SUS316

stainless steel

conventional carbon steel

10

11

pH

12

13

14

15

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Accelerated corrosion test in concrete

40deg, 10 NaCl solution, 18.5months stainless steel bars: SUS304-SD, SUS316-SD, SUS410-SD conventional carbon steel: SD295A bar diameter: D13 cover: 20mm concrete (W/C 50%)
40

Stainless Steel Bars

crack

20mm 10 NaCl 10% NaCl solution

10% NaCl solution specimen with crack

specimen without crack

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Results of accelerated corrosion test in concrete

not corroded not corroded

Stainless Steel Bars

stainless steel: SUS304-SD 18.5months, crack width 0.18mm

stainless steel: SUS316-SD 18.5months, crack width 0.18mm

not corroded

corroded

stainless steel: SUS410-SD 18.5months, crack width 0.18mm

conventional carbon steel 3months, crack width 0.20mm

Chloride concentration in concrete during the test

Concentrations of chloride ion (kg/m3) 25 20 15 10 5 0 0 5 10 15 duration time(months) SUS410L SUS316 SUS304

Stainless Steel Bars

seawater

20

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Proposed durability design of RC using stainless steel bars

Verification of corrosion resistance of RC structures by JSCE
w < wa
w: crack width wa: limit value of crack width

Stainless Steel Bars

Cd < Clim

Cd: design value of chloride concentration at location of reinforcement Clim: threshold value of chloride concentration for onset of corrosion

x reinforcement chloride ingress Clx Cd

C d = cl C 0 (1 erf ( 0.1 c d 2 Dd t ))

C(x,t) Chloride concentration

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Limit value of crack width (wa)

For conventional carbon steel reinforcement
Type of reinforcement Deformed bar Prestressing steel Environmental conditions for reinforcement corrosion Normal 0.005c 0.004c Corrosive 0.004c Severely corrosive 0.0035c

Stainless Steel Bars

For stainless steel reinforcement

Type of stainless steel SUS304-SD SUS316-SD SUS410-SD 0.5mm 0.5mm

c: cover < 100mm

Limit value of crack width

min (0.5mm, 0.005c)

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c: cover < 100mm

Stainless Steel Bars

Threshold value of chloride concentration for onset of corrosion (Clim)

1.2 kg/m3 is recommended for conventional carbon steel reinforcement Following values are recommended for stainless steel reinforcement
Type of stainless steel SUS304-SD SUS316-SD SUS410-SD Threshold value of chloride concentration for onset of corrosion (kg/m3) 15 24 9

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Mechanical properties of stainless steel reinforcement

strength fatigue strength stress-strain curve Young's modulus thermal expansion coefficient

Stainless Steel Bars

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Stress-strain curves
stress (N/mm2) (N/mm2 ) stress (N/mm2) (N/mm2 )
500 400 300 200 100 0 0 5000 10000
-6

Stainless Steel Bars

500 400 300 200 100 0 0 5000 10000

-6

D19 D25 SD345D19 15000 20000

D19 D25 SD345D19 15000 20000

(10 ) strain (x10-6) SUS340 -SD

similar with conventional stress (N/mm2) (N/mm2 )

500 400 300 200 100 0 0

(10 strain (x10)-6) SUS316 -SD

stress (N/mm2) (N/mm2 )

500 400 300 200 100 0 0

strain hardening
5000 10000
-6

D25 D19 SD345(D19 15000 20000

D25 D19 SD345(D19) 5000 10000

-6

15000

20000

(10 strain (x10)-6) SUS410 SD295

(10 ) strain (x10-6) SUS410 SD345

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Strength and stress-strain model for design

f yd =f yd +E u (- y ) =E s 0 y

Stainless Steel Bars

Stress-strain model for stainless steel reinforcement

f yd

= f yd
= E s

SUS410-SD295
f yk

except SUS410-SD295

Definition of strength of stainless steel reinforcement

Es 0 0.2%

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Fatigue properties

Stainless Steel Bars

SUS304-SD, SUS316-SD: higher fatigue strength SUS410-SD: fatigue strength is close to estimated by JSCE conventional design equation
JSCE equation can be used as well as conventional reinforcement. stress amplitude (N/mm2) (N/mm )
(N/mm ) stress amplitude (N/mm2)
400 350 300 250 200 150 100 0 500 1,000 1,500
3

350 300 250 200 150 100

0 500 1,000
3

JSCE eq. SUS304-SD SUS316-SD SUS410-SD

JSCE eq. SUS304-SD

f srd = 190

10 a Nk

sp s 1 f ud

f srd = 190

10 a Nk

sp s 1 f ud

N(10 ) number of loading at fracture N D19

(x103)

2,000

1,500

2,000

N(10 ) number of loading at fracture N

(x103)

D35

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Test on seismic performance of RC member using stainless steel

loading point longitudinal reinforcement (SUS304, D25)

Stainless Steel Bars

200

lateral reinforcement (SUS304, D13)

150 100

load (kN) N) reversed cyclic loading test of RC column specimen

50 0 -50 -100 -150 -200 -150

-100

-50

displacement (mm)

0 (mm)

50

100

150

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Stainless Steel Bars

LCC assessment of RC structure using stainless bars

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Stainless Steel Bars

Objective structure: piled pier

20.0 HWL +2.36
super structure

LWL +0.00

(unit: m)

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Calculation condition
Service life t (year) Concrete cover c (mm) concrete cement W/C
Conventional

Stainless Steel Bars

50 or 100 70 Ordinary Portland Cement 0.45

SUS410-SD SUS304-SD SUS316-SD

Reinforcement

Climkg/m3 Ddcm2/year
Surface chloride C0kg/m3

1.2

9 1.46 9 or 13

15

24

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Results: chloride concentration in concrete

Chloride concentration (kg/m3)

Stainless Steel Bars

In case that C0=13kg/m3:

conventional steel bars: corroded in 10years SUS410-SD: corroded at 43years other stainless bars: not corroded

SUS410

In case that C0=9kg/m3:

conventional steel year JAPAN SOCIETY OF CIVIL ENGINEERS

conventional steel bars: corroded in 10years stainless bars: not corroded

Stainless Steel Bars

Estimation of initial cost

1.6

Assumed material cost of stainless steel

Normalized initial cost

1.4 1.2 1 0.8 0.6 0.4 0.2 0

Conventional SUS410-SD SUS304-SD SUS316-SD N S-4 S-7 S-10

SUS304-SD: 7 times of conventional steel SUS316-SD: 11 times of conventional steel SUS410-SD: 4 times of conventional steel

Calculated initial cost of structure

SUS304-SD: 1.3 times of conventional structure SUS316-SD: 1.4 times of conventional structure SUS410-SD: 1.2 times of conventional structure

structures using stainless steel JAPAN SOCIETY OF CIVIL ENGINEERS

Results of LCC assessment 3 C0=9kg/m

4
S-7(SUS304) S-10(SUS316)

Stainless Steel Bars

LCC of structures using SUS304-SD, SUS316-SD, SUS410-SD are just equal to their Initial Cost because of no corrosion. B-1( Due to the maintenance cost, LCC of conventional structures B-2() are higher than that of structures using stainless steel. S-4(SUS410)
conventional steel + electrochemical corrosion protection conventional steel + surface coating LCC of structures using stainless steel
C0=9kg/m3
SUS410-SD S-4

LCC Normalized LCC

B-2 B-1

0 0 10 20 30 ( year 40 50 60 100

Results of LCC assessment 3 C0=13kg/m

4
S-7(SUS304) S-10(SUS316)

Stainless Steel Bars

LCC of structures using SUS304-SD, SUS316-SD are just equal to their Initial Cost because of no corrosion. B-1( Structure using SUS410-SD need to be repaired before 43 year B-2() due to reinforcement corrosion, which will affect its LCC. S-4(SUS410)
conventional steel + electrochemical corrosion protection

Normalized LCC LCC

3
B-2 B-1

conventional steel + surface coating

S-4

1
C0=13kg/m3
SUS410-SD

LCC of structures using stainless steel

0 0 10 20 30 ( 40 50 60 100

year

Stainless Steel Bars

Examples of concrete structures using stainless steel reinforcement

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Levee

Stainless Steel Bars

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Aomori Prefecture Museum

Stainless Steel Bars

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Stone cutters bridge (Hong Kong)

main tower (height: 298m)

Stainless Steel Bars

cable-stayed bridge (span: 1018m) 2882 ton of stainless steel reinforcements were used.

Design service life: 120years!

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Stainless Steel Bars

Kouri ohashi bridge (Okinawa, Japan)

severely corrosive environment, severe UV rays PC continuous box girder + PC rigid frame bridge (length: 1960m), constructed in 2004 Epoxy-coated reinforcements were mainly adopted. Stainless steel reinforcements were adopted in wheel guard portion considering UV ray attack during construction.

box girder segment JAPAN SOCIETY OF CIVIL ENGINEERS

Thank you for your kind attention

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