Making

Bharat
Atmanirbhar
Since 1970

Usage of Stainless steel in Bridges

1
 1. BRIDGES & FLYOVERS

2.STAINLESS STEEL

3. GLOBAL DEVELOPMENTS

INDEX 4.INDIAN initiatives

5.Focus areas

6.Domestic industry

7.Way forward

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1.BRIDGES & FLYOVERS

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 AGEING – RAILWAY BRIDGES
S.No. Ageing of Bridge Number Percentage
1 > 140 years 6,800 5%
2 > 100 Years Life 28,560 21%
3 81-100 years old 14,324 11%
4 61-80 years old 15,637 12%
5 Less than 60 years 70,297 52%
Total 135,618 100%

ROAD BRIDGES

1. 1,72,517 bridges/structures under Indian Bridge Management System (IBMS

2. Based on CRN , more than 30% of the bridges needs regular maintenance.
3. Aprox 3000 Nos are identified in Critical conditions.
4. More than 200 bridge tenders released in last 6 months for PMGSY
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2.Stainless steel
2.1.Need for Stainless Steel

2.2. Properties of stainless steel

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2.1. NEED FOR Stainless steel

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 CHALLENGING ENVIRONMENT

Source :
CECRI,Karaikudi
Large Coastline Vehicular and Industrial Pollution 7
 CORROSION OF STRUCTURE - A WORLDWIDE PROBLEM

Collapse

Fatal Taiwan bridge collapse

“Dangerous levels of corrosion” Not ascertained till it collapsed.

Just 20 years old 8
CORROSION OF STRUCTURE –
A WORLDWIDE PROBLEM

Washington State

I
Miami

Climate Change May See One In Four US

Steel Bridges Collapse By 2040*
•Source :
https://www.newscientist.com/article/2221040-climate-change-may-see-one-in-four-
us-steel-bridges-collapse-by-2040/#ixzz6Ntw22jcn
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FOOT OVER BRIDGE COLLAPSE

India
Factors
- Environment
- Corrosion
- Maintenance
- Load
Outcome
- Loss of Life
- Loss of Revenue
- Loss of Material

Andheri Foot Over Bridge , Mumbai

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 Stainless steel has been adopted world wide to
I

counter the issue of corrosion and light weight design.

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2.2.PROPERTIES OF STAINLESS STEEL

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 WHY STAINLESS STEEL DOES NOT RUST
What is Stainless Steel?
PASSIVE FILM on STAINLESS STEEL:
Oxygen
Stainless steel is an alloy of iron (Fe) and
Oxy-hydroxides of Fe and Cr
chromium (Cr).
2-3 nm thick
(0,002-0,003 µm)

Transparent
Adherent
Self repairing
Stainless Steel Surface Damage Self Repairing
Iron Chromium

SELF REPAIRING SURFACE

Ni, Mo and other alloying element to achieve desired properties

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Myths About Stainless Steel Truth About Stainless Steel

1. Life-cycle costing
1. Very Expensive materials  low cost solution

2.> 100 grades exist

2. Limited Grades  and in 4 families

3. Understanding is the key

3. Difficult to Form  formable, machine able

4. Understand corrosion
4. Never Rust  choose your grade

5. Both magnetic and non-magnetic

5. Non-magnetic  Austenitics are non-magnetic

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Family Of Stainless Steel

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 STAINLESS STEEL GRADES – STRUCTURAL APPLICATION

300 •304 : YS 210 MPA

Series
• 316 : YS 210 MPA

400 • IRS 350 CR: YS 350 MPA

Series

• 2205 : YS 450 MPA

Duplex
Series • 2304 : YS 400 MPA

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 RAILWAY EXPERIENCE – STAINLESS STEEL

%C % Mn %Ni, %Mo,
Grade Type %Cr %Cu PREN
Max Max Max Max
IRS 350 CR
(Indian Railway Stainless Steel 0.03 0.8-1.5 10.8-12.5 1.50 0.1-0.5 - 11
specification)
Corten Steel
Carbon Steel 0.20 0.75-1.30 0.30-0.50 0.50 - 0.20-0.40 -
(As per ASTM A588)
E 250
Carbon Steel 0.20 1.55 -- -- - - -
( As per IS 2062)

Extensively being used for Railway Wagons for Coal Transport

Alternative cost-effective solution for construction of bridges as it offers combination of high toughness,
good weldability, high strength and corrosion resistance

PREN = %Cr + (3.3 x %Mo) + (16 x %N)

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 SUPERIOR MECHANICAL PROPERTIES
Yield Strength Ultimate Tensile Strength % Elongation Impact Toughness (J) at Room
Grade
(MPA) (Min) (MPA) (Min) (Min) Temp (Min)

IRS 350 CR 350 500 25 60

E 250 245 310 22 27
Corten Steel 250 320 22 30

- Excellent Impact Resistance

- Equivalent or higher strength

IRS 450CR with YS 450 Mpa has been developed

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 SUPERIOR CORROSION RESISTANCE

0.6
0.51
0.5
Corrosion loss(mmpy)

0.4 0.37

0.3
0.2
0.1
0.01
0
Carbon Steel Corten Steel IRSM 44-97
IRS 350 CR

IRS 350CR is expected to give 37 times more life than Carbon Steel in Normal conditions
More than 20 times in coastal areas

*Corrosion Performance of Various Steels as per Test SAE J2334 consisting of alternating wet/dry cycles with salt for 8 weeks
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3.GLOBAL DEVELOPMENTS

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 INTERNATIONAL REFERENCES OF USAGE OF
ASTM A1010(IRS 350 CR) FOR BRIDGES
Year of Span Plate Thickness
Location Why A1010
Construction (m) (mm)
One foot clearance over canal,
Colusa County, Ca, over local canal 2004 11.5 4-25
thin section
Salt use, excessive time of
Coatesville, Pa, Steel plant, over local creek 2012 15 9.5-38
wetness
Astoria,Oregon,Hwy.138 and Dodge Creek 2012 Excessive time of wetness 39.5 12.5-45

Oregon,U.S.Rte.30 and Mill Creek 2013 Marine area 36.5 12.5-38

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Ref: Stainless steel for accelerated bridge construction from Mittal Steel
Bridge Name: Arch Bridge
Bridge Location: London
Type : Duplex Stainless steel
Bridge Name: Coateville Bridge
Bridge Location: USA
Type : Ferritic Stainless steel
Bridge Name: Colusa County Bridge
Bridge Location: USA
Type : Ferritic Stainless steel
4.Indian initiatives

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 BHAYANDER FOB - STATUS
1. RDSO approved Material Grade IRS 350 CR for structural applications

2. Design Basis Report approved from IIT/RDSO/Western Railway

Project Details:

Thickness Range 8mm to 40mm

Grade IRS 350 CR

Welding Process SAW

SATISFACTORY RITES INSPECTION REPORT OF MATERIAL

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 Flange – 25 mm
Welded Portion

Welded
Web – 16mm portion

PLATE GIRDERS
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 LIFE CYCLE COST ANALYSIS

Stainless Steel is not expensive if the Life Cycle Cost is taken into account
The Cost of other materials substantially increases over time while the
cost of Stainless Steel normally remains constant
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 70 MTR SPAN FOB: LIFE CYCLE COST ANALYSIS

1. Initial cost increase is 20-25% over existing carbon steel, However, savings over service
life of 60 years is 35-40%. However, Service life of Stainless steel is more than 100 years.

2. Low maintenance over carbon steel . For aesthetics purpose , Paint is recommended for
utility Ferritic stainless steel. For Duplex stainless steel , no need of painting.

3. Weight Reduction of more than 25-30% achieved due to higher Yield Strength and light
weight design

4. Payback period is less than 20 years.

5. Stainless steel is green material and increase in reducing Carbon Foot Print

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 Railway FOB Project updates
1. Tender Status of FOB Projects (97 Projects)
a. Tenders Awarded : 8 (Bhynder, Thane,Kalyan,Tuticorin,VOC Nagar,
Himalaya(BMC).Srikakulam,Naupada)
b. Tender opened but not finalised : 3(Hijili ,Soro )
c. Tenders awaiting financial approval : 2 (Ladowal,Kishanganj)
d. Tender expected in this month : 4 (Jaipur,Kanjurmarg,Dharavi,Sion).
e. Active cases : 80 (All zonal Railways)

1. Railway board has taken target

to construct 80 FOBs from all
zones and 14 ROBS from 7
zones.
2. Railways target FY 20-21
circular indicates that Corrosion
is everywhere.

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 MCGM Stainless steel Bridge Projects
Type of Bridge Project name Grade
FOB Himalaya IRSM44/97(m)
Flyover Goregaon East west flyover Duplex 2205
Skywalk Bandra IRSM44/97(m)
Flyover S U B Vile
- Parle Duplex 2205
HEADING
Flyover H E R Borivali
E West IRSM44/97(M)
Flyover Borivali West Duplex 2205
Flyover Suspension bridge -bandra Duplex 2205
Flyover vidhyavihar bridge Duplex 2205
Flyover Malad east west bridge Duplex 2205
Flyover Ghokle Bridge Duplex 2205
Flyover Kandiwali road bridge Duplex 2205
Flyover Borivali bridge Duplex 2205
Flyover Vashi toll plaza entrance gate work Duplex 2205
Flyover Chembur Oswal naka nagar Duplex 2205
Flyover Devnagar Project + Tilak nagar station IRSM44/97(M)
1. MCGM and Structural consultant adopted stainless steel for various projects

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 Mrinaltai - Mumbai Flyover
First Stainless steel Vehicular Bridge in Duplex Grade

SUB-
HEADING
HERE

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 LUCKNOW SMART CITY

 ALAMBAGH , HAZRATGANJ, MAHANAGAR BOYS SITE – LOCATION OF THE PROPOSED

STAINLESS STEEL FOBS.

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5.FOCUS AREA (ECOSYSTEM)
5.1 STANDARDS
5.2 MANUALS
5.3 CODES
5.4 LCC POLICY

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STANDARDS

A1010M (IRS 350 CR)

Stainless steel incorporated
as a structural steel for
Bridges

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MATERIAL CODE – A1010M

Higher Yield strength – 345 MPA

variant of Stainless steel Plate

Element % ASTM A1010

Carbon 0.03 max

Manganese 1.5 max

Phosphorous 0.04 max

Sulphur 0.01 max

Silicon 1.0 max

Chromium 10.5 – 12.5

Nickel 1.5 max

Nitrogen 0.03 max

Molybdenum 0.1 min*

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MANUALS

Validation for adoption of stainless steel in

structures – Design Manual available by AISC

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 RDSO SPECIFICATION FOR STRUCTURAL STAINLESS STEEL
1. Material Specification : BS-S-7.5.3.1-9
2. Grade Name: IRS 350 CR

https://rdso.indianrailways.gov.in/view_section.jsp?lang=0&id=0,5,268,5443,5445,5467
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 Railway Circular – Corrosion Policy

1. Railway Board issued circular to

all Zonal Railways for using
Stainless steel in corrosion prone
areas

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 RDSO Approved Standard Drawings

1. FOB (The following 2 span covers over 70% of total FOB requirement)
a) 25-30 mtr lengthX6mtr wide Span – Completed.
b) 20-25 mtr lengthX6mtr wide Span – Completed.
c) Special instruction to Zonal railways for using the same drawings
for3mtr wide spans.

2. ROB (The following 2 span covers over 70% of total ROB requirement)
a) 36X11 Span – Completed

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 RDSO Approved SS FOB Drawing (30mtr span)

1. RDSO Approved Drawing

for 30X6 mtr span

2. Grade – IRS 350CR

3. Qty – 105mt -30X6mtr

4. Staircase,Column,Girder,R
oof supporting structure –
All stainless steel

5. Designs uploaded and

circulated to all Zonal
railways.

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 RDSO Approved SS ROB Drawing (36mtr span)

1. RDSO Approved Drawing

for 36X11 mtr span

2. Grade – IRS 350CR

3. Designs uploaded and

circulated to all Zonal
railways.

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 STAINLESS STEEL STANDARDS

Material Codes
EN 10088 (all parts)
ASTM A1010/A1010M
ASTM A709/A709M
ASTM 240
BS-S-7.5.3.1-9 (IRS 350 CR)
Corresponding Design Code
EN 1993-1-1(General Design Rules),EN
1993-2 (Steel Bridges) & EN 1993-1-4
(Supplementary rules for Stainless
steels
AASTHO LRFD Bridge Design
Specifications
AASTHO LRFD Bridge Design
Specifications
Corresponding Construction /
Fabrication Code
EN 1090-2: Execution of steel structures
(Technical Requirements for Steel
Structures)
AASTHO LRFD Bridge Construction
Specifications
AASTHO LRFD Bridge Construction
Specifications

 New Material Standard proposal for Structural stainless steel has been submitted to BIS by
ISSDA. Draft preparation is under progress
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 LCC POLICY CIRCULARS

Source: https://doe.gov.in/divisions/adoption-principles-life- Source: Manual for procurement of Goods 2017 45

cycle-cost-lcc-analysis
6.Domestic industry

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 CAPACITIES AVAILABLE

DOMESTIC
CAPACITIES

Steel Melting 3,700,000

HOT ROLLING CAPACITY 3,500,000

Adequate Capacity available in India to meet the demand of FOBs/ROBs 47

 Domestic Capability

PRODUCTS Width(mm) Thickness(mm)

Max Min Max
Plates/Sheets 1500 2 80

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 Domestic Capability – Ancillary Items
Size Ranges
CAPACITIES

Nuts M4 to M16 to Higher (All Specification)

BOLTS M3 to M16 To Higher ( All Specification)

WASHERS All sizes available
Screws & Rivets M4 to M16 To Higher (All Specification)

RE BARS All sizes Available

AngLEs & Channels CRF Sections, Fabricated Sections Available

Welding CONSUMABLES All sizes & Grades available

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 Fabricated Plate Girders

Ecosystem already exists – RDSO/IRC approved

workshops

JSL can also supply fabricated plate

girders & other sections

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 Stainless Steel – Chequered Plates/Sheets

SS HR 409M CHEQUERED PLATES STAINLESS STEEL CR EMBOSSED

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7.JSL commitment

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 Design
Support
Fabricator Training to
Identification Fabricators

Raw Material
JSL Certifications
Support
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7.Way forward

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WAY FORWARD TO SUSTAINABLE GROWTH

Incorporation of
Stainless Steel as
preferred material

Identification of 10
Set examples for other upcoming bridge
states projects to be taken up
on trial basis

Formation of close
Adoption of RDSO
action group to promote
standards for structural
SS in varied infra
stainless steel
applications

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 INDUSTRY IS COMMITTED
Contact us:

Nagarajan Periasamy
(+91) 8130757806

infra@jindalstainless.com

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FIRST INITIATIVE TAKEN BY INDIAN RAILWAY FOR FOB & ROB