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Preliminary Assessment of Durability of Sustainable RC Structures with Mixed-in Seawater and Stainless Steel Reinforcement
F. Lollini*, M. Carsana*, M. Gastaldi*, E. Redaelli*, L. Bertolini*, A. Nanni^
* Politecnico di Milano, Department of Chemistry, Materials and Chemical Engineering “Giulio Natta”, Milan, Italy
^ University of Miami, Civil Architectural and Environmental Engineering, Miami, USA
The 8th International Conference on Concrete under Severe Conditions-Environment & Loading
12-14 September 2016 – Politecnico di Milano, Lecco, Italy
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Introduction
Concrete plays a remarkable socio-economic role in the world. More than 18B tons of concrete are nowadays produced every year, requiring large amounts of natural resources.
new cements and mineral additions
Can we save natural resources?P
rodu
ctio
n(1
06t)
worldwide cement production
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Introduction
Concrete plays a remarkable socio-economic role in the world. More than 18B tons of concrete are nowadays produced every year, requiring large amounts of natural resources.
Can we save natural resources?
Approximately 1.5 trillion liters of freshwater are used annually in concrete production for mixing, curing and equipment cleaning.
Water
Worldwide, construction and demolition wastes make about 30% of the total.
Recycled concrete aggregate (RCA) is abundant.
Aggregates
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Introduction
Chlorides in seawater cause de-passivation of the steel and consequent corrosion phenomena. We need to prevent corrosion by limiting the initial chloride content in concrete and designing durability by preventing chloride penetration.
Concrete itself could become a more sustainable material, allowing:- the use of seawater for mixing and curing- the use of salt-contaminated recycled concrete aggregates (RCA)- the use of cements without chloride restriction (e.g. use solid waste as kiln fuel as well as adding kiln dust back to the clinker)- ...
Technology development over the last two decades has made available FRPs and stainless steels to replace the conventional black steel reinforcement when the durability of a structure is of concern.
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Research program
Research project - Within the framework of ERA-NET Plus Infravation, an infrastructure innovation program on “Advanced systems, materials and techniques for next generation infrastructure”, the SEACON project -Sustainable concrete using seawater, salt-contaminated aggregates, and non-corrosive reinforcement was recently started.
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Research program
This project aims at demonstrating the safe utilization of seawater and salt-contaminated aggregates (natural or recycled) for a sustainable concrete production when combined with non-corrosive reinforcement to construct durable and economical concrete infrastructures.
Research project - Within the framework of ERA-NET Plus Infravation, an infrastructure innovation program on “Advanced systems, materials and techniques for next generation infrastructure”, the SEACON project -Sustainable concrete using seawater, salt-contaminated aggregates, and non-corrosive reinforcement was recently started.
Long-term experimental tests2 field
demonstration projects
(USA and Italy)
LCALCC+ +
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Research program
This presentation – Considering the lack of sufficient fresh water in many regions of the world, this paper focuses on a preliminary evaluation of the possibility of replacing fresh water used to mix concrete with seawater, combined with different types of stainless steel reinforcement.
This project aims at demonstrating the safe utilization of seawater and salt-contaminated aggregates (natural or recycled) for a sustainable concrete production when combined with non-corrosive reinforcement to construct durable and economical concrete infrastructures.
Research project - Within the framework of ERA-NET Plus Infravation, an infrastructure innovation program on “Advanced systems, materials and techniques for next generation infrastructure”, the SEACON project -Sustainable concrete using seawater, salt-contaminated aggregates, and non-corrosive reinforcement was recently started.
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Case study
Environmental exposure:
Materials:
Splash zone Mediterranean Sea
portland cement (w/c = 0.45)fly ash cement (w/c = 0.45)
CEMENT
Reinforcing bars
fresh waterseawater
waterType UNS EN Approx. comp. Microstructure
XM‐28 S24100 ‐ 18%Cr‐12%Mn Austenitic
304L S30453 1.4311 18%Cr‐10%Ni Austenitic
23‐04 S32304 1.4362 23%Cr‐4%Ni Duplex
22‐05 S32205 1.4462 22%Cr‐5%Ni Duplex
+ Reference black steel bars
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fib Model code design equation - Selection of input values
02
100,
0,0 tDxderfCCCClPgPp
app
cxsthf
Dapp (diffusion coefficient):
C0 (initial chloride content) 1% by mass of binder (seawater)
t (service life)
dc (concrete cover thickness)
Limit state: corrosion initiation
Cl-
+ -
no Cl-
cls
DRCM (rapid chloride migration coefficient)
0
5
10
15
0.40 0.45 0.50 0.55 0.60 0.65
DR
CM
(10-1
2m
2 /s)
water/binder ratio
OPC
FA
Cement content:300 kg/m3
350 kg/m3
F. Lollini et al., Constr. Build. Mater., 120, 2016
Cs,Δx (chloride content at a depth Δx)
00.5
11.5
22.5
33.5
44.5
0 1 2 3 4 5 6 7 8 9 10 11
Freq
uenc
y (%
)
Cs (% by mass of binder)
F. Lollini et al., Constr. Build. Mater., 79, 2015
black steel30422-0523-04XM-28
Clth (critical chloride threshold)
0
1
2
3
4
5
6
0 5 10 15
Freq
uenc
y (%
)
Clth (% by mass of binder)
M. Gastaldi et. al., 3rd ACI Workshop on New Boundaries of Str. Concr., Bergamo 3-4 October 2013.
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Pf vs time for mean concrete cover of 45 mm (w/c = 0.45)
Portland cement
freshwater seawater
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Initiation time (year)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Initiation time (year)
black steel304L22-0523-04XM-28
Time (year)
Fly ash cement
P0 = 10%
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150Pr
obab
ility
of f
ailu
re (%
)Initiation time (year)
black steel304L22-0523-04XM-28
Time (year)
P0 = 10%
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Service life calculated for dc = 45 mm and Pf = 10%
fresh water seawaterfresh water seawater
0
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Initi
atio
n tim
e (y
ear)
Portland cementFly ash cement
0
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Initi
atio
n tim
e (y
ear)
0
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Initi
atio
n tim
e (y
ear)
304L 22-05 23-04 XM-28
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Pf vs mean concrete cover for tSL = 50 years (w/c = 0.45)
Portland cement
black steel30422-0523-04XM-28
Fly ash cement
black steel30422-0523-04XM-28
freshwater seawater
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150
Prob
abili
ty o
f fai
lure
(%)
Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150Pr
obab
ility
of f
ailu
re (%
)Concrete cover thickness (mm)
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150Pr
obab
ility
of f
ailu
re (%
)Concrete cover thickness (mm)
P0 = 10% P0 = 10%
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Mean concrete cover required for Pf = 10%
tsl = 50 y tsl = 100 y
fresh water seawater
fresh water seawater
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Con
cret
e co
ver
thic
knes
s (m
m)
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Con
cret
e co
ver
thic
knes
s (m
m)
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Con
cret
e co
ver
thic
knes
s (m
m)
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28
Con
cret
e co
ver
thic
knes
s (m
m)
Portland cementFly ash cement
20
40
60
80
100
120
140
160
black steel 1.4307 1.4462 1.4362 XM-28C
oncr
ete
cove
r th
ickn
ess
(mm
)
Portland cementFly ash cement
304L
22-05 23-04 XM-28 304L 22-05 23-04 XM-28
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Conclusions
A preliminary assessment of the durability of RC elements made with mixed-in seawater and exposed to the splash zone in a temperate climate was carried out by means of a probabilistic performance-based approach, assuming literature values for the critical chloride threshold of stainless steels and no effect of seawater on the diffusion coefficient.
Using conventional concrete, several design options were found to be suitable to reach target service lives of 50 or 100 years, by using different grades of stainless steel reinforcement, which allowed the use of reasonable values of concrete cover thickness.
The use of seawater as mixing water led to a modest increase of the required concrete cover thickness in comparison to the use of fresh water, which depended on the type of stainless steel, showing that various combinations of concrete composition and stainless steel grade may suitable.
The choice of the most appropriate design option could be made through LCA and LCC analyses. Such analyses as well as validation of the hypothesis made for the input parameters in this work will be carried out within the SEACON project.