Corrosion resistant structure for soil reinforcement

Abstract: Method for the realization of soil reinforcement by means of cathodically polarized stainless steel unitsfeaturing high corrosion resistance. The method applied foresees the use of stainless steel and carbon steel strips.

Description: The technique for soil reinforcement, invented by Henry Vidal and known as "Reinforced Earth" (a deposited trade mark by Terre Armée Internationale S.A.), is used in the construction of supporting walls, railway embankments, sea-breakers, quays, dams, barriers, etc., and is obtained by sinking flat strips of metal into the ground during the construction so as to act as real structural units (H. Vidal, US Patent 3 421 326.) The principle consists in combining a granular material, soil, with tensile resistant units, the reinforcement, so as to form a new composite building material. Owing to the adhesive forces between the reinforcement and the soil particles, this composite material can withstand very great loads, according to the reinforcement's resistance characteristics. The metal presently used is nearly exclusively bare C-steel, or, preferably galvanized carbon steel, that is coated with a thick layer of zinc applied by hot dipping. This type of corrosion protection ensures durability up to 100 years, as is often required, as long as the soil used is not corrosive (J.M. Jailloux, "Durability of Materials in Soil Reinforcement Application", 9th European Congress on Corrosion, Utrecht 2 - 6 October 1989; M. Darbin et al, "Durability of Reinforced Earth Structures: the Results of a Long-term Study Conducted on Galvanized Steel", Proc. Instn. Civ. Engnrs, Part 1, 1988, Vol. 84, Oct., 1029-1057). In reference to this aspect, considering that the project life can be limited only by the durability of the reinforcement, design tenders specify the characteristics the soil used must comply with (M. Macori et al., "Durabilità delle Opere d'Arte Stradali", ANAS, Direzione Generale, Roma February 1988), namely: resistivity above 1000 ohm/cm (M. Darbin et al, "Durability of Reinforced Earth Structures: the Results of a Long-term Study Conducted on Galvanized Steel", Proc. Instn. Civ. Engnrs, Part 1, 1988, Vol. 84, Oct., 1029-1057), or 3000 ohm/cm (M. Macori et al., "Durabilità delle Opere d'Arte Stradali", ANAS, Direzione Generale, Roma February 1988). residual water pH between 5 and 10 chloride content - less than 200 mg.kg-1 sulphate content - less than 1000 mg.kg-1 total sulphides expressed as sulphur concentration: less than 300 mg.kg-1 no clays no organic substances. The need to use soils with well defined characteristics that can ensure negligible corrosion of the metal reinforcement represents a meaningful economic burden, especially where soils with the features required are not available. Also, in some cases, although one has used a "specific" soil free of aggressive species, the external environment may, in time, alter these characteristics, polluting the soils with chloride salts for example, as is common in coastal areas or, on roads as a result of the use of de-icing salts. Other environmental pollution phenomena such as "acid rain" make the problem even more complex. The results are a progressive increase of the soils corrosivity that in more or less long periods can cause the corrosion of the reinforcement thus affecting the mechanical resistance of the entire structure. For example a striking case (G.E. Blight, M.S. Dane, Deterioration of a Wall Complex Constructed of Reinforced Earth", Geotechnique, vol. 39, n. 1, pp. 47-53, 1989) which occurred a bare 18 months after completion describes the corrosion of zinc-coated steel reinforcement in Reinforced earth. The corrosive attack, which was first recognized as localized corrosion, caused the progressive deterioration of the structures, which led to its being demolished and rebuilt after only 8 years. Corrosion was caused by a striking aggressiveness of the soil; in fact, owing to the difficulty of locally acquiring soil with the features normally required, a less strict tender was accepted with a durability of the structure limited to thirty years only and the following limits for the soil: pH 5 - 10; resistivity above 500 ohm/cm; chlorides less than 1500 mg.kg-1; sulphates less than 800 mg.kg-1; the use of sea water to compact the soil. In these conditions, added to the presence of clays and sands that formed differential aereation cells, localized corrosion phenomena took place rapidly. Even the cathode protection technique normally used in corrosion prevention for steels placed in soil, sea-water, concrete etc. is not easily applicable in the case considered for a number of technical and economic reasons, amongst which: the difficulty in realizing electric contact between the steel reinforcements to be protected and the anodes, both of the sacrificial or of the impressed current type; the excess in consumption of traditional sacrificial type anodes (practically only the magnesium type) relative to the need for the carbon steels to reach immunity: this condition, for bare surfaces, that is non coated, signifies high protection current density and thus heavy consumption also related to the extremely protracted project lives, for example 100 years, required for these structures. difficulty in access in case of replacement of exhausted anodes; difficulties in current and potential distribution on the cathode structure, that is the reinforcement strips which in the earth make up a tight and geometrically complex network, (especially in the case of cathode protection by means of impressed current). In the past, to solve the corrosion problem, metal materials alternative to zinc coated carbon steel have been tried out. So stainless steels featuring a chromium content equal to, or above 12%, were tried, but were definitely insuccessful (J.M. Jailloux, "Durability of Materials in Soil Reinforcement Application", 9th European Congress on Corrosion, Utrecht 2 - 6 October 1989; M. Darbin et al, "Durability of Reinforced Earth Structures: the Results of a Long-term Study Conducted on Galvanized Steel", Proc. Instn. Civ. Engnrs, Part 1, 1988, vol. 84, Oct., 1029-1057). In fact these materials which normally operate in so-called "passive" conditions, that is covered by a protective chromium oxide film, are subject to localized corrosion, especially by chloride ions, and secondly, by sulphate reducing bacteria. This situation can be further worsened by the presence of clays that feature poor oxygen transport, thus favouring the formation of active-passive macro-cells. This type of localized corrosion dramatically reduces the mechanical resistance of the metal unit, and, paradoxically, the damages may well be worse than those produced by a generalized corrosion attack, as is normal with zinc coated carbon steel. Therefore the use of stainless steels was hastily abandoned. The use of polymer materials is also being studied; however their use requires a great number of tests and studied especially concerning their long term stability. For all the above reasons corrosion of reinforcement structures represents a considerable burden in terms of the requirements of soil characteristics, and in any case represents a risk during the operative life owing to the possible changes of the soil's aggressivity. GB-A-1,485,004 describes a reinforced earth structure and a method of constructing thereof, wherein stainless steel or glass reinforced plastics may be used for the stabilizing members. GB-A-2,022,615 describes an austenitic stainless steel partly covered with a dissimilar less noble stainless steel for use in an environment different from that of the present application. The new solution is that of utilizing stainless steel appropriately cathodically polarized. It is a known fact that cathodic polarization prevents the initiation of localized corrosion, keeping the stainless steel in so called "perfect passivity conditions", that is, stable both in relation to localized corrosion and generalized corrosion (P. Pedeferri, "Corrosione e Protezione dei Materiali Metallici", CLUP, Milano 1978; L. Lazzari, P. Pedeferri, "Protezione Catodica", CLUP, Milano, 1981). In order to examine the corrosion performance of stainless steels one should bear in mind the so called "anode characteristic" of the material, and the parameters known as passivation potential - Ep, pitting potential Er, and the protection potential - Epp. Figure 1 shows on potentials logarithm of the current density diagram, the typical anodic characteristic of a stainless steel in an environment such as sea-water or an aggressive soil. The figure clearly shows how when the natural potential falls within the Er - Ep interval the material operates in passive conditions, that is, the current associated to the anodic process is very low, equal to ip, and the corrosion rate is negligible. On the other hand, when the natural potential has values above those of the pitting potential, Er, the material is subject to pitting localized corrosion. Within the potential interval between Er and Ep also the potentials above and below Epp are made evident, the latter is known as perfect passivity or pitting protection potential. Within the potential interval between Er and Epp the material is in conditions of "imperfect passivity": there are risks of localized corrosion, and above all, once these have begun they will spread and make repassivation impossible; below Epp on the contrary there are conditions of "perfect passivity" and thus no possibility of localized corrosion. The Er, Ep and Epp parameters are obviously characteristic to the type of stainless steel and to the environment in which it is employed. According to the above said the polarization of the metallic materials in the cathodic direction, and more precisely from the potential of "free corrosion" to that of a potential below Epp, in perfect passivity, eliminates all risks of corrosion. If we refer to sea-water, that can most certainly be conservatively assimilated to a highly corrosive soil, the aim is to bring the potential of the more common stainless steels (austenitic, martensitic, ferritic, precipitation hardening, austeno-ferritic, etc.) to values around -0.200 - -0.500 V vs Cu/CuSO₄ saturated reference electrode. A more accurate definition of the pitting protection potential depends on the type of stainless steel and the type of soil; in any case we remain in polarization conditions which are considerably lower than those needed for the protection of carbon steels (-0.850 V vs Cu/CuSO₄) saturated In these conditions we can certainly state that stainless steel features the required characteristics for use with all types of soil realistically to be encountered with Reinforced Earth, above all with soils with less strict corrosion requirements than those currently enforced and thus more easily found. The invention consists therefore in a metal reinforcement for use in an earth reinforcement method, said reinforcement having the features listed in the appended claim 1. The invention further relates to a method having the features listed in the appended claim 10 and to the reinforced structures manufactured by said method. The term stainless steels defines those iron-based alloys featuring the following composition expressed as a percentage of the alloying elements: chromium 11 - 35 % nickel 35 % max molibdenum 7 % max copper 3 % max alluminium 1 % max titanium 1 % max niobium 1 % max tungsten .5 % max carbon .5 % max sulphur .05 % max phosphorous .05 % max silicon 2.5 % max manganese 3 % max nitrogen .4 % max iron balance The specific chemical composition of a given stainless steel and the heat treatment it undergoes defines the type of microstructure it shows: the following classes of stainless steel are considered, defined on the basis of their microstructures: martensitic, austenitic, ferritic, bi-phasic austenoferritic, superaustenitic, precipitation hardening. Within each of these classes one can distinguish materials with different features depending on the heat treatment operations, and above all to hardening by cold working. (A. Cigada, G. Re "Metallurgia", Vol. II, CLUP, Milano 1984). It is preferable to obtain the polarization according to the so-called "sacrificial anode" principle, where the power for polarization is provided by the battery formed by coupling the metal to be protected with another less electrochemically noble metal. One material which can be specifically used as sacrificial anodes, apart from the traditional aluminium, zinc, and magnesium, is carbon steel. The latter features in the soil a spontaneous potential in the -0.400 - -0.600 V range vs Cu/CuSO₄. The specific advantage represented by carbon steels is that its natural potential is close to that of stainless steels, and therefore the protection effect is reached within the terms required without an excessive consumption of anodic material. In these conditions the carbon steel takes on an anodic behaviour and the stainless steel acts as a cathode; the effect is the production of a low current short circuit current which corresponds on the electrodic surfaces to the reduction of oxygen on the cathode (stainless steel), and an anodic dissolution of the carbon steel strip. In the soil the circulation of the current is supported by the migration of ion species dissolved in water: positive charged ions shall migrate towards the cathode and those negatively charged towards the anode. This last aspect plays a particularly important role in maintaining the steel anode surfaces active: in fact the chloride ions, that concentrate close to the anode surfaces, help prevent passivation of the iron, which might reduce or cancel the difference in potential with the stainless steel. The quality of the stainless steel chosen for a specific structure, and the device for cathodic polarization, both determine the level of corrosion resistance and thus the overall reliability of the system. One can state that given the same polarization conditions the risks of a localized corrosion attack will be all the lower the higher the pitting potential of the stainless considered will be. In this sense stainless steels may be classified according to the "Pitting Resistance Equivalent" parameter, defined on the basis of the chromium, molibdenum and nitrogen content (P. Wilhelmsson et al., "Sandvik SAF 2304 - A High Strength Stainless Steel for the Engineering and Construction Industries", A.B. Sandvik Steel, R&D Centre): that is: P.R.E. = Cr% + 3.3Mo% + 16N% In a preferred realization the invention consists of a reinforcement for earth made up of a bi-metallic strip consisting of stainless steel strip of the austeno-ferritic type and a carbon steel strip. From a mechanical resistance point of view the entire load will be borne by the stainless steel strip, and this must be considered in calculating width and thickness of the stainless steel strip. Whereas the thickness of the carbon steel only has an electrochemical function as a sacrificial anode; its size therefore shall respond to durability requirements according to the design life planned. These bi-metallic elements (stainless steel and carbon steel strips) can be produced by co-lamination, spot welding or continuous welding between the two metals, or with any other suitable method so as to ensure electric contact between the two metals. The finished product may also be completed by cross bars and heading so as to increase its adherence to the soil. This realization offers the specific advantage of solving the difficulties in electrically connecting the anodes, whether these are of the sacrificial type or those with impressed current. Thus ensuring uniform distribution of the current and the potential throughout the reinforcement. In a similar realization of the bi-metallic element, the cathodic surface, that is the external surface - soil side - of the stainless steel element is painted. Paint application, as proposed here, is not foreseen for anti-corrosion purposes, as is traditional, but it is specifically recommended in order to reduce areas to be cathodically protected and, consequently, to reduce the average galvanic, i.e. protection, current. This means lower consumption of the sacrificial carbon steel strip, thus allowing to limit relevant sizes and weights. Obviously design shall be based on a linear coating break-down, to take into account the loss of paint effectiveness in time. The term paint here defines paints in general as well as all types of non metallic coating and lining suitable for application on the stainless steel strip. As for the metal fittings of the strips to the concrete face; bolts, nuts or brackets; these can remain as designed and need no modifications. As for the materials they can be manufactured according to traditional techniques, that is, in galvanized carbon steel, or, in case of particularly aggressive environments, also in stainlees steel, preferably of the austeno-ferritic type. In this case, the brackets can also be made in bimetallic material. The invention is illustrated at Figure 2 in one of its possible forms of realizatiopn, where the bi-metallic reinforcement is made up by stainless steel strip (1), thickness S1, and by colaminated carbon steel strip (2), thickness S2; the reinforcement is then completed by a number of cross bars (3), that increase the adherence to the soil; the hole (4), at the end of the strips are for anchorage to the face. A second embodiment is shown in Figure 3, where the two stainless steel and carbon steel components are assembled by means of spot welding (5) (the other numbers show the same points as Figure 2). In Figure 3, to increase the adhesion between soil and reinforcement the headed zones (6), were added, their thickness is S3. EXAMPLE 1 The case refers to the construction of a coastal barrier with Reinforced Earth, exposed to a typical sea climate and thus subjected to contamination of the soil by chloride salts. The traditional project featured carbon steel strips, hot zinc coated, width 50 mm and thickness 6 mm. Out of the overall thickness, 3 mm represented the added thickness for corrosion allowances, while the remaining 3 mm were needed for the applied load in consideration of the fact that the yield strength (Rp 0.2) for the carbon steel being examined is 240 N.mm⁻² min. From the dimensions of the working section and the yield strength the mechanical resistance calculated for the strips is 36.000 N. To ensure corrosion resistance for the entire project life, 100 years, the structure was realized with reinforcement made up by bi-metallic strip units made of Sandvik SAF 2304 (deposited trademark of A.B. Sandvik Steel, Sweden) in annealed conditions and carbon steel. The SAF 2304 (P. Wilhelmsson et al., "Sandvik SAF 2304 - A High Strength Stainless Steel for the Engineering and Construction Industries", A.B. Sandvik Steel, R&D Centre) stainless steel features a higher resistance to localized corrosion than the traditional types AISI 304L and 316L (P.R.E. equal to 24.6 for SAF 2304, 24.3 for AISI 316L and 18.4 for AISI 304L). The mechanical resistance of the element is ensured by the stainless steel strip that features a yielding strength (Rp 0.2) at least (Rp 0.2) 400 N.mm⁻². To ensure a tensile resistance to that calculated for the galvanized carbon steel structure, a section 60 mm wide and 1.5 mm thick was chosen. The carbon steel unit, acting as a sacrificial anode is 3 mm thick and is spot welded every 500 mm. The size of the carbon steel unit was chosen assuming that the protection current density would be 10 mA.m⁻² as the anode consumption of 10 g.mA⁻¹.year⁻¹; the consumption of carbon steel is calculated on the basis that the project's current density will be used for the reduction of oxygen on the stainless steel surface, on one side, and on the carbon steel, on one side, (current possibly absorbed by the two metal surfaces facing each other was considered insignificant, because in the gap local oxygen transportation will be considerably hindered). The bi-metallic reinforcement realized as described where checked one year after installation and featured a uniform corrosion rate on the earth-side steel, equal to 15 microns; whereas the stainless steel unit showed no corrosion at all, neither generalized nor localized.

Claims: Metal reinforcement to be specially used with an earth reinforcement method called "Reinforced Earth®" (dep. trade mark), the metal reinforcement being constructed of a bi-metallic structure consisting of an actual reinforcement unit (1) in stainless steel coupled to a unit (2) of a less electrochemically noble metal acting as a sacrificial anode for the cathodic polarization of the stainless steel in the field of perfect passivity. Reinforcement according to claim 1, in which said stainless steel is of the martensitic, or austenitic, or ferritic or bi-phasic austeno-ferritic, or superaustenitic, or precipitation hardening, with possible cold hardening, the main components of the alloy being: chromium 11 - 35 % nickel 35 % max molibdenum 7 % max copper 3 % max aluminium 1 % max titanium 1 % max niobium 1 % max tungsten .5 % max carbon .5 % max sulphur .05 % max phosphorus .05 % max silicon 2.5 % max manganese 3 % max nitrogen .4 % max iron balance Reinforcement according to claim 1 or 2, in which the sacrificial anode unit (2) is made of carbon steel. Reinforcement according to anyone of claims 1 to 3, in which the reinforcement unit (1) is specially made of Sandvik SAF 2304 (deposited trade mark) austeno-ferritic stainless steel, in an annealed or hardened condition. Reinforcement according to any of the above claims 1 to 4 where the reinforcement unit (1) which acts as cathode, is painted or coated or lined in order to reduce protection current requirements and sacrificial anode consumption. Reinforcement according to any of the above claims 1 to 5 in which the bi-metallic contact between unit (1), stainless steel, and the sacrificial anode (2) is obtained by means of colamination. Reinforcement according to any of the above claims 1 to 5 in which the bi-metallic contact between unit (1), stainless steel, and the sacrificial anode (2) is realized by continuous or spot welding at distances between 50 and 2000 mm. Reinforcement according to any of the above claims 1 to 7 in which the bi-metallic structure (1-2) features any number of cross bars (3) and/or headed areas (6) in order to increase the adherence of the structure to the soil. Reinforcement according to any of the above claims 1 to 8 in which the bi-metallic structure features at least one hole (4) for anchorage to the concrete face in the construction of wall structures. Reinforcement according to any of the above claims in which the metal fittings for anchorage of the bimetallic structure to a concrete face are made of stainless steel or bimetallic. Reinforcement method called "Reinforced Earth®" characterized in that a metal reinforcement according to any one of the above claims 1-10 is used. Reinforced structures comprising a metal reinforcement according to any one of claims 1 to 10, manufactured by the method according to claim 11.

Inventors: BAZZONI BRUNO, LAZZARI LUCIANO, PEDEFERRI PIETRO, RONCHI GAETANO, SALA GIUSEPPE, BAZZONI, BRUNO, LAZZARI, LUCIANO, PEDEFERRI, PIETRO, RONCHI, GAETANO, SALA, GIUSEPPE
Applicants: CESCOR CENTRO STUDI CORROSIONE, SANDVIK ITALIA SPA, SANDVIK ITALIA S.P.A.
Application year: 1990
Main classification: E02D29
IPC codes: E02D29, C23F13