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Publication Number: FHWA-HRT-06-078
Date: June 2006

Job Site Evaluation of Corrosion Resistant Alloys

(508 Compliance)

May 2006

Figure 1: Bar Graph. Distribution of information acquisition and analysis for the IBRC projects. The graph shows the number of IBRC projects for each of the eight notes listed in table 1. Note 1 had five conforming projects; notes 2, 6, and 8 each had one conforming project; note 3 had seven conforming projects; notes 4 and 5 each had eight conforming projects and note 7 had two conforming projects.

Figure 2: Graph. Accelerated testing data for type 2201 stainless steel specimens. Plot of polarization resistance parenthesis RP end parenthesis parenthesis ordinate end parenthesis versus exposure time parenthesis abscissa end parenthesis for accelerated corrosion testing of Type 2201 stainless steel compared to data for Type 316 stainless steel and black bar. A second ordinate plots chloride concentration. Type 2201 surface conditions include as received, iron shot blasted, silica sand blasted, and stainless steel shot blasted. Data for Type 2201 silica sand blasted bars that were obtained from the Jensen Beach Causeway project are also shown. For the black bars, RP was initially about 3 times∙10 to the power of 3 ohms per square centimeter and decreased to 8 times 10 to the power of 2 ohms per square centimeter after 84 days exposure. For Type 316 stainless steel, RP was relatively constant with time and in the range 1 times 10 to the power of 6 to 1 times 10 to the power of 7 ohms per square centimeter. For the Jensen Beach Causeway bars, RP was in the range 3 times 10 to the power of 4 to 1 times 10 to the power of 5 ohms per square centimeter during the initial 50 days of exposure and subsequently increased to the range 1 times 10 to the power of 5 to 2 times 10 to the power of 5 ohms per square centimeter. For the as-received and iron and stainless steel blasted bars, RP was in the same range as for the Jensen Beach Causeway ones initially but after about 50 days tended to decrease slightly with further exposure. For the silica sand blasted Type 2201, RP was in the range 1 times 10 to the power of 5 ohms per square centimeter for the initial 50 days but then decreased to the same range as for the other surface conditions.

Figure 3: Graph. Accelerated testing data for MMFX-II steel specimens. Plot of polarization resistance parenthesis RP end parenthesis parenthesis ordinate end parenthesus versus exposure time parenthesis abscissa end parenthesis for accelerated corrosion testing of MMFX-II parenthesis trademark end parenthesis bars from IBRC projects PR-02, OK-01-01, and DE-00-01 and for bars supplied directly to this laboratory compared to data for Type 316 stainless steel and black bar. A second ordinate plots chloride concentration. The MMFX-II RP data tended to decrease with time from an initial range of 1 times 10 to the power of 4 to 1 times 10 to the power of 5 ohms per square centimeter to 3 times 10 to the power of 3 to 1 times 10 to the power of 4 ohms per square centimeter with job site bars occupying the lower bound.

Figure 4: Graph. Accelerated testing data for stainless steel job site bars. Plot of polarization resistance parenthesis RP end parenthesis parenthesis ordinate end parenthesis versus exposure time parenthesis abscissa end parenthesis for accelerated corrosion testing of stainless steel bars from job sites compared to data for Type 316 parenthesis non-job site end parenthesis and black bar. A second ordinate plots chloride concentration. Polarization resistance data for Type 2205 job site bars were about one order of magnitude greater than for laboratory received bars of this same alloy and in the range 3 times 10 to the power of 5 to 1 times 10 to the power of 6 ohms per square centimeter. Data for Type 316 clad bars were about an order of magnitude below those for the laboratory received solid bar counterpart and in the same range as for the Type 2205 job site bars.

Figure 5: Bar Chart. Cost comparison of the various reinforcements. The chart compares the cost of the different job site corrosion-resistant reinforcements with values as listed in the text.

Figure 6: Photo. Side view of Bridge Number 1-119 on SR 82 crossing Red Clay Creek in Ashland, New Castle County, Delaware.

Figure 7: Photo. View of the deck of Bridge Number 1-119 on SR 82 in Ashland, New Castle County, Delaware, with MMFX-II reinforcement in place.

Figure 8: Photo. General view of in-place reinforcement, girders with studs, curb, and bulkhead for Bridge Number 1-119 on SR 82 in Ashland, New Castle County, Delaware.

Figure 9: Photo. Closeup view of reinforcing steel, girder with shear studs, gusset plate, and forming for bulkhead for Bridge Number 1-119 on SR 82 in Ashland, New Castle County, Delaware.

Figure 10: Photo. View of reinforcing steel and a girder with studs for Bridge Number 1-119 on SR 82 in Ashland, New Castle County, Delaware.

Figure 11: Photo. Closeup view of in-place reinforcing steel showing superficial corrosion for Bridge Number 1-119 on SR 82 in Ashland, New Castle County, Delaware.

Figure 12: Photo. View of MMFX-II reinforcement details acquired from the Bridge Number 1-119 job site.

Figure 13: Photo. Perspective view of replacement Bridge Number 890146 parenthesis East Relief Bridge end parenthesis crossing the Saint Lucie River at Jensen Beach, Florida.

Figure 14: Photo. View of substructure components prior to decking for Bridge Number 890146 parenthesis East Relief Bridge end parenthesis crossing the Saint Lucie River at Jensen Beach, Florida.

Figure 15: Photo. View of MMFX-II deck steel in place for Bridge Number 890146. parenthesis East Relief Bridge end parenthesis crossing the Saint Lucie River at Jensen Beach, Florida.

Figure 16: Second view of MMFX-II deck steel in place for Bridge Number 890146 parenthesis East Relief Bridge end parenthesis crossing the Saint Lucie River at Jensen Beach, Florida.

Figure 17: Photo. View of stored MMFX-II reinforcing steel at the job site for Bridge Number 890146 parenthesis East Relief Bridge end parenthesis crossing the Saint Lucie River at Jensen Beach, Florida.

Figure 18: Photo. Perspective of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis under construction.

Figure 19: Photo. View of driven, cut-off prestressed piles for pier 11 of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 20: Photo. View of formwork, piles, and reinforcement being placed in the footer of pier number 12 of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 21: Photo. View of formwork, piles, and reinforcement being placed in the footer of pier number 12 of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 22: Photo. View of 2201 stainless steel in place at the base of the footer formwork of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 23: Photo. View of 2201 stainless steel reinforcement cage for the column of pier number 11 of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 24: Photo. Closeup view of a portion of the 2201 stainless steel reinforcing bars in the column cage prior to placement in pier number 11 of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 25: Photo. View of the conventional bar reinforcement cage for a hammerhead column cap of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 26: Photo. View of pier number 11 column formwork and 2201 stainless steel cage in place of the Jensen Beach Causeway Bridge parenthesis Bridge Number 890145, Frank A. Wacha Bridge end parenthesis.

Figure 27: Photo. View of type 2201 rebars positioned in salt fog chamber at the Florida Department of Transportation Corrosion Laboratory.

Figure 28: Photo. View of type 2201 rebars 1A and 1B after salt fog testing. Bar 1A was shot blasted with carbon steel and shows rusting over 98 percent of its surface. Bar 1B was similarly shot blasted and then pickled and shows rust spots on 3 percent of its surface.

Figure 29: Photo. View of type 2201 rebars 2A and 2B after salt fog testing. Bar 2A was as-rolled and shows rusting over 98 percent of its surface. Bar 2B was also as-rolled and then pickled. It shows light rusting on 2 percent of its surface.

Figure 30: Photo. View of type 2201 rebars 3A and 3B after salt fog testing. Bar 3A was silica sand blasted and shows light rusting over 5 percent of its surface. Bar 3B was silica sand blasted and then pickled. It shows light rusting on 1 percent of its surface.

Figure 31: Photo. View of type 2201 rebars 4A and 4B after salt fog testing. Bar 4A was silica sand blasted and shows light rusting over 5 percent of its surface. Bar 4B was silica sand blasted and then pickled. It shows light rusting on 1 percent of its surface.

Figure 32: Photo. General view of NBI Bridge Number A6059 on Route 6 crossing Medicine Creek and an adjoining field runoff stream near Galt, Missouri, approximately 100 miles northwest of Kansas City.

Figure 33: Photo. Side view of Bridge Number 6059 on Route 6 crossing Medicine Creek and an adjoining field runoff stream near Galt, Missouri, approximately 100 miles northwest of Kansas City.

Figure 34: Photograph of the deck of Bridge Number 6059 with Type 316LN stainless steel in place.

Figure 35: Photo. View of the deck on NBI Bridge Number P00001180+0.399-1 crossing the Middle Fork of the Flathead River on US 2 near Essex, Flathead County, Montana, with type 2205 stainless steel reinforcement placement in progress.

Figure 36: Photo. View of bundled/wrapped bars at the job site for NBI Bridge Number P00001180+0.399-1.

Figure 37: Photo. View showing carbon steel shear studs protruding through bottom mat of stainless steel reinforcement on NBI Bridge Number P00001180+0.399-1.

Figure 38: Photos: Examples of rust spots on reinforcement. Figure 38A shows bundled bent bars in opened cardboard container. Figure 38B shows straight reinforcement in place on NBI Bridge Number P00001180+0.399-1.

Figure 39: Photo. View showing cardboard packaged bent reinforcement details for NBI Bridge Number P00001180+0.399-1.

Figure 40: Photo. View of a guard angle adjacent to an expansion joint on NBI Bridge Number P00001180+0.399-1.

Figure 41: Photo. View showing array of plastic chairs to which bars from both mats are tied on NBI Bridge Number P00001180+0.399-1.

Figure 42: Photo. Closeup view of a plastic chair to which bars are tied on NBI Bridge Number P00001180+0.399-1.

Figure 43: Photo. View of stainless steel reinforcement details acquired from the job site of NBI Bridge Number P00001180+0.399-1.

Figure 44: Photo. General view of Bridge Number 185/077 (I-293/NH101 WB) on I-293 over Brown Avenue in Manchester, New Hampshire, under construction.

Figure 45: Photo. View of the in-place girders on the Brown Avenue Bridge, Bridge Number 185/077 parenthesis I-293/NH101 WB end parenthesis. Epoxy-coated reinforcement is seen extending from the top of the backwall.

Figure 46: Photo. In-place galvanized deck reinforcement on Bridge Number 180/089 parenthesis I-293/NH101end parenthesis on I-293 over Frontage Road in Manchester, New Hampshire.

Figure 47: Photo. View of bundled/wrapped bars at the Frontage Road job site.

Figure 48: Photo. Fabricated galvanized bars at the Frontage Road Bridge job site.

Figure 49: Photo. View of stored galvanized bars at the Brown Avenue Bridge job site.

Figure 50: Photo. View of as-delivered galvanized bars at the Brown Avenue site after pulling back the plastic wrap.

Figure 51: Photo.Closeup view of the in-place galvanized reinforcement relative to carbon steel studs.

Figure 52: Photo. View showing deposits on the galvanized reinforcing bars.

Figure 53: Photo. View of in-place bottom galvanized rebar mat with plastic mat spacer.

Figure 54: Photo. View showing examples of disbonding of the galvanized layer on fabricated bars for the Brown Avenue Bridge.

Figure 55: Photo. Galvanized layer disbonding and "icicles" on reinforcing bars.

Figure 56: Photo. General view of NBI Bridge Number 26415 over the Chickaskia River on I-35 in Kay County, Oklahoma.

Figure 57: Photo. View of in-place deck reinforcing steel on NBI Bridge Number 26415 over the Chickaskia River on I-35 in Kay County, Oklahoma.

Figure 58: Photo. Closeup view of MMFX-II deck reinforcing steel on NBI Bridge Number 26415.

Figure 59: Photo. View of reinforcing steel as placed in the deck and parapet wall on NBI Bridge Number 26415.

Figure 60: Photo. Perspective view of steel storage for NBI Bridge Number 26415.

Figure 61: Photo. View of stored bars on timbers at the job site for NBI Bridge Number 26415.

Figure 62: Photo. General view of NBI Bridge Number 107005400100 under construction on S-54 parenthesis Chisolm Road end parenthesis over Tidal Creek in Charlestown County, South Carolina.

Figure 63: Photo. View of MMFX-II placement in Span 5 of NBI Bridge Number 107005400100.

Figure 64: Photo. View of 2205 stainless steel placement in Span 2 of NBI Bridge Number 107005400100.

Figure 65: Photo. View of in-place clad stainless in Span 3 of NBI Bridge Number 107005400100.

Figure 66: Photo. View of in-place black bars parenthesis Span 1 of NBI Bridge Number 107005400100 end parenthesis along with discrete galvanic anodes.

Figure 67: Photo. Closeup view of discrete galvanic anodes on in-place Span 1 black bars of NBI Bridge Number 107005400100.

 

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