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[email protected] – mcd.chem.polimi.it 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 8 th International Conference on Concrete under Severe Conditions-Environment & Loading 12-14 September 2016 – Politecnico di Milano, Lecco, Italy
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[email protected] – mcd.chem.polimi.it

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

[email protected] – mcd.chem.polimi.it

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.

[email protected] – mcd.chem.polimi.it

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.


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