duplex stainless steels for structural engineering
TRANSCRIPT
Duplex Stainless steels for structural engineeringDaniel Reuithe
Market Development
Outokumpu
09-13
9/15/2016
Contents
Duplex grades for structural engineering
Typical structural applications
Case study: Life cycle cost of using duplex in bridge design vs. carbon steel
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It all took off with 2205 in the 80s…
Storage & pressure equipment
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Product performance comparison
strength
corrosion
resistance
PRE = % Cr + 3.3 x % Mo + 16 x % N. Yield strength (Rp0.2) uses EN 10088-2 minimum values for cold rolled strip
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600
550
500
450
400
350
300
250
200
150
Du
ple
xA
uste
nitic
Core
304L/4307
Supra
316L/4404 Ultra 317L
Ultra 4439
Ultra 904L
Ultra 254 SMO
Forta LDX 2101 EN 1.4162/S32101
Forta DX 2304EN 1.4362/S32304
Forta DX 2205EN 1.4462/S32205
Forta SDX 2507EN 1.4410/S32750
Forta LDX 2404EN 1.4662/S82441
Corrosion Resistance, CPT typical [°C]
Str
en
gth
, R
p0
.2 [
MP
a]
Hot Hot Hot Hot rolledrolledrolledrolled coilcoilcoilcoil
Forta EDX 2304EN 1.4362/S32304
0 10 20 30 40 50 60 70 80 90
Higher strength
Matchincorrosioresistan
The duplex range today vs. austenitics
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uplex benefits in structural engineerin
• High mechanical strength (Rp min > 400 MPa)
• High durability (corrosion and wear resistance etc.)
• Good fabricability
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Critical design aspects to consider• Inclusion in relevant product standards and
design codes:
o Pressure vessels: PED/EN 13345, ASME VIII etc.
o Storage tanks: EN 14015, API 650 etc.
o Steel structures: Eurocode 3 etc.
o Offshore structures: Norsok etc.
• Design temperature range: ≈ -40 to 300°C
• Welding practice
• Availability of complementary products
• Performance criteria vs. material cost:
o Strength utilization(Allowable design strength vs. stiffness/instability)
o Adequate corrosion resistance (2205 >> 316L > 304L)
o Initial investment cost vs. life cycle cost
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Typical structural applications for dupleProcess industry:
Storage tanks and
pressure equipment
Infrastructure: Bridges,
flood and sluice gates
etc.
Offshore industry:
Topside structural
components etc.
Established grades:
LDX 2101, DX 2304,
2205, SDX 2507
New potential grade:
LDX 2404
Established grades:
LDX 2101 and DX 2205
New potential grade:
LDX 2404
Established grades:
DX 2304 and DX 2205
New potential grade:
EDX 2304
Infrastructure: Re
Established grades:
LDX 2101, DX 2304,
DX 2205
New potential grade:
EDX 2304
Efficience in chemical cargo switchingFinbeta SpA, Italy
Outokumpu has made the world’s first full-package delivery
pre-polished duplex plate sections for chemical tankers.
Marina Bay Bridge, SingaporeMarina Bay Bridge, SingaporeMarina Bay Bridge, SingaporeMarina Bay Bridge, Singapore
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Aesthetics without maintenance costs
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Reliable transportation with stainless steel railway bridge
Añorga Bridge – Spain, 2011
Old bridge in carbon steel replaced due to:
Heavy corrosion damage
Heavy maintenance demand
New bridge in Outokumpu high performance
stainless steel:
120 year design life
Minimized maintenance
Light weight (high strength)
Thickness 12-23 mm, 130 tons
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Tammerkoski rapid channels rehabilitation project
Sluice and floodgates that take hydropower to 21st
century standards
• Old channels used in hydropower generation were rebuilt
new sluice and floodgates in Outokumpu Duplex stainless
steel
• Ensures uninterrupted, largely maintenance-free service fo
two centuries
• High strength – thinner material
• Operating lighter gates require less hydraulic force
• Good abrasion resistance
• Excellent corrosion properties
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Stainless Rebar – extending bridge lifespan to 300 years
Construction’s lifespan multiplied
Stainless rebar used at most critical bridge structures
– pylon splash zones
Dramatic Life Cycle Cost reduction for whole project
Increasing designed technical lifespan to 300 years
More freedom for innovative design due to high
strength and qualities of stainless steel (LDX 2101®)
in Concrete Reinforcement.
Courtesy of Leighton Abigroup Joint Venture
ABN
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Forta EDX 2304 – example of Lean Duplexsteel used offshore
• Very positive customer response
• Forta EDX 2304 type of grade, lean duplex steels with
PRE ≥ 28, expected to replacing 316-materials in the
Johan Sverdrup project in the North Sea
NORSOK qualified up to 35 mm, being further
developed up to 80 mm.
Available up to 100 mm
Availability Recent updates
Grade G 48E, CPT G 48F, CCT G 150, CPT
Supra 316L/4404 20°C <0°C 20°C
Forta DX 2304 25°C <0°C 25°C
Forta EDX 2304 30°C 5°C 36°C
Reference design: Composite Highway Bridge
(SCI Publication 357)
Carbon steel Duplex Lean Duplex
S355 DX 2205 LDX 2101
Bridge design:
• Based on reference design by SCI, in this study
redesigned and optimized in accordance with
EC3
LCC parameters:
• 60 year service life
All maintenance and inspection cost based on indus
practice for 4 different scenarios: minor, major road,
marine and railway
• Repainting of carbon steel
• Discount rates from UK government guidance
• Life cycle maintenance cost discounted to net prese
value *Study conducted by Arup U
Fa
Total
Initial Cost
Material
cost
Tota
Life Cycl
Fabr
co
Life cycle cost of using duplex in bridge desig
• Weight savings of 27% by using
duplex in optimized steelwork design
• 2% lower steel work cost
for the optimized LDX 2101 design
Fabricatio
cost
Total
Initial Cost
Material
cost
Fabrication
cost
Bridge steel work cost*
*Study conducted by Arup UK,
Material
Fabrication & Erection
Corrosion protection
Reference
S355
Optimized
LDX 2101
Optimized
2205
100
200
300
400
500
-2%
+19%Ref.k€
Fabrication
cost
Total
Initial Cost
Material
cost
Total
Life Cycle Cost
Fabrication
cost
Operating
Mainte
cost
Bridge life cycle maintenance cost*
*Study conducted by Arup U
• Significantly reduced maintenance
over
60 year service by using duplex
• Potential LCC cost savings of mor
than 30% by using duplex SS
Life cycle
maintenance cost S355
Life cycle
maintenance cost LDX 2101/DX 2205
Conclusions
Higher mechanical strength of duplex: improves structural efficiency in loadbearing components (tanks, bridges etc.) when designed according to applicable code (where duplex grades are well covered)
Adequate corrosion resistance of duplex:provides durability for critical components from mildly corrosive to harsh environments: LDX 2101/DX2304/EDX 2304/LDX 2404/DX 2205/SDX 2507No protective coatings needed – less maintenance – longer service life
Higher fabrication efficiency with duplex: thinner gauges – less welding and coating free surfaces shorten fabrication time
Duplex grades provide cost effective and sustainable solutions
for structural applications
uplex inclusion in relevant design codesStandard Applicatio
n
Material
standard
LDX 2101EN 1.4162/ S32101
DX 2304EN 1.4362/S3204
EDX 2304EN 1.4362/S32304
LDX 2404EN 1.4662/S82441
DX 2205EN 1.4462/S32205
SDX 2EN 1.4410/
EN 14015 Storage
tanks
EN 10088-1
and -2Yes* Yes Yes** No Yes Yes
API 650/620 Storage
tanks
ASTM A240 Yes Yes Yes** No Yes Yes
ASME VIII-1 Pressure
vessels
ASME SA240,
II-D or Code
Case
Yes Yes Yes Yes Yes Yes
ASME VIII-2 Pressure
vessels
ASME SA240,
II-D or Code
Case
No No No No Yes Yes
EN 13445 Pressure
vessels
EN 10028-7 Yes* Yes Yes** Yes* Yes Yes
-1-
Eurocode
Steel
structures
EN 10088-4 Yes* Yes Yes** Yes*** Yes Yes****
NORSOK Offshore No No Yes No Yes Yes
* LDX 2101 (EN 1.4162) included in the next revision of EN 14015, EN 1993-1-4 and EN 10028-7.** EDX 2304 can be used according to specification for EN 1.4362 or S32304.
*** LDX 2404 (EN 1.4662/S82441) included in the next revision of EN 1993-1-4 a**** SDX 2507 (EN 1.4410) can be used according to the next revision of EN 19910% higher safety factor.