Corrosion resistance of microcomposite and duplex stainless steels for reinforced concrete bridge decks.

摘要

Chloride-induced corrosion of reinforcing steel in concrete is one of the major durability concerns in reinforced concrete structures. In Northern America, the cost of maintenance and replacement for highway bridges due to corrosion damage is measured in billions of dollars. Of corrosion protection systems, reinforcing steels with inherently good corrosion resistance have received increased attention.; In this study, the corrosion performance of two systems, MMFX microcomposite steel and duplex stainless steels including 2101 and 2205 duplex steels in both "as-rolled" and pickled conditions, were compared with that of conventional and epoxy-coated steel using laboratory tests. These tests include rapid macrocell tests, corrosion potential tests, bench-scale tests (the Southern Exposure and cracked beam tests), and two modified versions of the Southern Exposure test to determine the critical chloride threshold. The rapid macrocell tests were modified by replacing the simulated concrete pore solutions at the anode and cathode every five weeks to limit the effects of changes in the pH of the solutions. The corrosion resistance of the steels was evaluated based on the corrosion rates, corrosion potentials, mat-to-mat resistances, and critical chloride thresholds measured in these tests. Based on laboratory results, along with data from bridge deck surveys and field experience, the service lives of the steels for bridges decks were estimated and the cost effectiveness was compared based on a life-cycle cost analysis.; Results show that, in all rapid macrocell tests, replacing the test solution helps maintain the pH and reduces the corrosion rate and loss of steel. It is recommended that the test solution be replaced every five weeks. Statistically, effective chloride thresholds for reinforcing steel can be determined based on chloride samples from modified Southern Exposure and beam specimens.; Results show that conventional steel has the lowest corrosion resistance, with chloride thresholds ranging from 0.91 to 1.22 kg/m3 (1.53 to 2.05 lb/yd3) on a water-soluble basis. Epoxy-coated steel [with four 3.2-mm (0.125-in.) diameter holes in the coating in each test bar to simulate defects of 0.2 to 1% of the bar area] has good corrosion resistance, with corrosion losses ranging from 0.4 to 6% of the values for conventional steel. MMFX microcomposite steel exhibits higher corrosion resistance than conventional steel, with corrosion losses between 16% and 66% and chloride thresholds, 3.70 to 4.07 kg/m3 (4.72 to 6.86 lb/yd3 ), equal to three to four times the value of conventional steel. (Abstract shortened by UMI.)