Structural Stainless Steel Workshop Summary. Nancy Baddoo Associate Director, SCI October 2012

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1 Structural Stainless Steel Workshop Summary Nancy Baddoo Associate Director, SCI October 2012

2 What is stainless steel? Corrosion resistant steel with Cr content >10.5% More than 200 grades, but only a few grades are used in construction

3 Why use stainless steel? Corrosion resistance and long life Maintenance and inspection is difficult Attractive metallic surface Hygienic properties Non-magnetic properties Good toughness at very low temperatures

4 Structural applications of stainless steel Buildings (commercial, residential, leisure) Transportation (airports, stations) Bridges Industry (food & drink, chemical, oil & gas, nuclear, water, biogas etc)

5 Stainless steel reinforcing bar Highway bridges, overpasses, tunnels Car parks Wharfs, piers Coastal buildings Historical building restorations Buildings with sensitive electronic equipment

6 Stainless steel reinforcing bar BENEFITS Longer design life of structure (> 100 years) Reduced concrete cover reduced deck weight reduced substructure weight

7 Chinese stainless steel material standards GB/T Stainless and heat-resisting steels designation and chemical composition GB/T Hot rolled stainless steel plate, sheet & strip GB/T Cold rolled stainless steel plate, sheet & strip

8 Common grades in construction Name Relative cost Basic Cr-Ni austenitic Cr-Ni-Mo austenitic L L Lean duplex Duplex

9 Austenitic grades 304 and 304L 316 and 316L Standard Cr-Ni grade Cr-Ni-Mo grade Most common grade in construction Suitable for rural and light urban environments Widely used grade in construction Suitable for urban, industrial and coastal environments L = low carbon content Suitable for cryogenic applications Available in a wide range of product forms

10 Duplex grades Lean duplexes, e.g Relatively new, not yet widely used in construction Cr with very low additions of Ni & Mo Corrosion resistance between 304 & 316 Available in a few product forms Most common duplex grade, but not yet widely used in construction Highly alloyed Cr-Ni-Mo-N Suitable for severely corrosive environments e.g. heavy industrial, coastal, de-icing salts Available in a reasonably wide range of product forms Twice as strong as austenitic grades

11 Characteristics of groups used in construction Group Strength Ductility Magnetic Weldable Formability Austenitic Duplex

12 Grade selection 1 1) General environment & direct surroundings - distance from sea - presence of de-icing salts - exposure to washing from rain - access for maintenance & inspection 2) Strength 3) Welding and fabrication

13 Grade selection 2 4) Surface finish - Less risk of staining/pitting with smoother finish 5) Customer s expectations - Aesthetic requirements - Design life 6) Product form and availability within given time - Not all grades available in all product forms/sizes

14 Grade selection 3 7) Temperature of operation - High temps might speed up corrosion - Low temps need a grade with good toughness 8) Special requirements - Non-magnetic properties 9) Cost - Material cost and whole life costs

15 Does stainless steel ever stain or corrode? If the wrong grade is selected for the environment, or if there is exposure to unexpected conditions or if the component is not cleaned, then... some grades may be susceptible to localised corrosion

16 Pitting Starts as tiny points of attack Usually in chloride environments Rarely leads to structural damage Corrosion products cause surface staining Prevent by: - Appropriate grade selection - Regular cleaning

17 Crevice Corrosion Stagnant solutions build-up of chlorides and lack of oxygen Between nuts and washers, around the thread of a screw, under deposits on steel surface Prevent by: - Appropriate grade selection - Careful detailing no crevices

18 Poor detail Good detail Detailing for durability

19 Bimetallic (Galvanic) Corrosion Metals in contact of different electro-chemical potential in a conducting liquid Less noble metal (anode) corrodes faster than if metals not in contact Area effect Prevent by: - Excluding water (painting/taping) - Isolating the metals

20 Detail to prevent bimetallic (galvanic) corrosion Stainless steel bolt and nut Insulating gasket Insulating washer Stainless steel washer Carbon steel plate Insulating bushing Stainless steel plate Stainless steel washer

21 Stress-Strain Characteristics low strain σ 80 ksi (552 MPa) Duplex Duplex stainless steel 60 ksi (413 MPa) 40 ksi (276 MPa) Austenitic stainless steel Austenitic Carbon steel A36 20 ksi (138 MPa) Strain ε (%)

22 Stress-Strain Characteristics high strain

23 Min. Specified Mech. properties Grade Strength N/mm 2 Ductility % Stiffness N/mm 2 Austenitic stainless 304 and 304L , and 316L Duplex stainless Lean duplex e.g , Carbon steel S ,000

24 Stainless steel fasteners EN ISO :2009 Mechanical properties of corrosion-resistant stainless steel fasteners. Bolts, screws and studs GB/T idt ISO :1997 ASTM F738M-02 Standard specification for stainless steel metric bolts, screws and studs No standard currently for duplex stainless steel bolts

25 How sustainable is stainless steel? Durability and low maintenance (Economic) Appearance (Social) No coatings needed (Environmental, Economic) Recyclable and reusable (Environmental) - Very high end-of-life recycling rates due to high value - 100% recyclable - No change in inherent properties Factory production (Environmental, Economic, Social) - minimum waste - high standards of health and safety

26 Design standards Eurocode 3 Eurocode 3 Part 1.4: 2006 Design of steel structures. Supplementary rules for stainless steels Welded, hot rolled & cold formed members Austenitic, duplex (and ferritic) grades Modifies and supplements rules for carbon steel where necessary Applies to buildings, bridges, tanks etc

27 Design standards - US ASCE/SEI 8-02 Specification for the Design of Stainless Steel Cold-Formed Structural Members SCI has written an AISC Design Guide for hot rolled and welded structural stainless steel which aligns to ANSI/AISC Specification for Structural Steel Buildings

28 China design standard for structural stainless steel Under development. Organised by China Association for Engineering Construction Standardization Contributions from: - Central Research Institute of Building Construction, MCC Group, China Jingye Engineering Co. - South East University of China - Taiyuan Steel Corporation - Tsinghua University - and others

29 Stainless steel exhibits fundamentally different behaviour to carbon steel

30 Design strength of stainless steel Minimum specified 0.2% proof strength in material specification Stress 0.2 Grade 304, f y = N/mm 2 Grade 316, f y = N/mm 2 Grade 2205, f y = N/mm 2 E 0.2% E Strain

31 Design of stainless steel members Follow same basic approach as carbon steel Some differences in section classification limits, local buckling and member buckling curves apply due to: - non-linear stress strain curve - strain hardening characteristics - different levels of residual stresses

32 Comparison of AISC column buckling curves for stainless and carbon steel Stainless steel Carbon steel

33 Comparison of AISC lateral torsional buckling curves for stainless and carbon steel Carbon steel Stainless steel

34 Deflections Non-linear stress-strain curve means that stiffness of stainless steel as stress Deflections are greater in stainless steel than in carbon steel Use secant modulus for the maximum stress in the member at the serviceability limit state (SLS)

35 Design of bolted connections Rules for carbon steel bolts in clearance holes can generally be applied to stainless steel (tension, shear) Special rules for bearing resistance required to limit deformation due to high ductility of stainless steel

36 Design of welded connections Carbon steel design rules can generally be applied to stainless steel Use the correct consumable for the grade of stainless steel

37 Strength reduction at high temperatures Carbon steel k f y, θ y,θ/f y Stainless steel

38 Stiffness reduction at high temperatures k E, θ E E Carbon steel Stainless steel

39 Thermal expansion Austenitic stainless steels expand more than carbon steel In structural frames, restraint will exist from surrounding members Additional forces are therefore likely to result Precautions to minimise weld distortion

40 Prevent contamination by carbon steel pick-up Iron particles from carbon steel tools embed in surface of stainless steel and rusts within hours/days stainless steel appears to be rusting Ideally, use dedicated fabrication area Avoid contact with carbon steel lifting tackle, grinding wheels, wire brushes etc Protective plastic coatings can be specified

41 Welding Cleanliness/absence of contamination important Follow approved weld procedures Use qualified welders EN Arc welding stainless steels AWS D1.6/D1.6M Structural welding code - stainless steel

42 Welding stainless to other metals Use over-alloyed electrode to ensure adequate mechanical properties and corrosion resistance Painted carbon steel remove paint from weld area to reduce hazards from weld fume, and after welding paint over the joint a few cm onto stainless steel

43

44 12 Structural Case Studies (in Chinese)

45 Resources for structural engineers European Design Manual - Design guidance - Worked examples - Commentary - Online design software Stainless in Construction Information Centre

46 Design guidance aligned to British Standards - Guidance - Design examples - Tables of section properties Online design software:

47 Erection & Installation of Stainless Steel Components Computer aided learning on stainless steel: Fabrication of duplex stainless steels

48 Summary (1) Stainless steel is a corrosion resistant steel alloy Stainless steel is used in construction: - in aggressive environments, - where maintenance is difficult - for architectural reasons Different grades are suitable for different environments

49 Summary (2) Design standards are available Structural performance: similar to carbon steel but some modifications needed due to non-linear stress-strain curve At high temperatures, stainless steels lose strength and stiffness at a different rate to carbon steel at higher temperatures they perform better

50 Summary (3) Similar fabrication techniques as for carbon steel Take care to avoid contamination with carbon steel Resources are available to help you! some in Chinese, some in English, e.g. Case studies, design guidelines, etc

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