Design for Service Life,

Bridge Birth Certificate &

Concrete Structures
Management Concepts
Presented by: Mike Bartholomew, PE
CH2M HILL
AASHTO Bridge Sub-Committee Meeting
T-9 Technical Committee for Bridge
Preservation
July 6, 2009
New Orleans, LA
1

Discussion Topics

Service Life Design

Work Being Done in Europe

Current US Practice
Exposure Conditions
Deterioration Mechanisms / Protection Systems
Mathematical Modeling
Limit States / Design Process

Bridge Birth Certificate

Purpose
Documentation Examples & Templates
Integration with Inventory Management
Systems
2

 fdration

internationale du bton
(The International Federation for
Structural Concrete)
Writing new Model Code to include
Service Life Design
Publication of 1st draft scheduled for
The Third International fib Congress
Washington, DC
May 29 to June 3, 2010
3

fib Commission 5:
Structural Service Life Aspects
Some

key areas of interest

Probabilistic performance based service

life design.
Service life management.
Inspection, assessment and
performance monitoring.
Development and validation of
deterioration mechanisms.

What do these Bridges have in

common?

Answer
Although

not similar in:

Structure Type
Materials
Age
Geographic Locations
They

are all:

Deteriorating with time

6

Service Life (Durability) Design

fib Bulletin 34 Model Code for Service
Life Design (2006)
Establishes design procedures

to Resist Deterioration
from Environmental Actions

In 4 Levels of Design
Full Probabilistic
Partial Factor
Deemed to Satisfy
Avoidance of Deterioration
7

AASHTO LRFD Service Life

(Durability) Design Requirements
2.5.2.1.1

The contract documents

shall call for quality materials and for
the application of high standards of
fabrication and erection.
Structural steel shall be self
protecting or have long-life coating
systems or cathodic protection.
8

AASHTO LRFD Service Life

Design Requirements
C2.5.2.1.1

The intent of this Article

is to recognize the significance of
corrosion and deterioration of
structural materials to the long-term
performance of a bridge.
Durability also mentioned in C5.4.2.1
and 5.12.1.

AASHTO LRFD Service Life

Design Requirements
Expectations

for durability exist

All recommendations qualify as
deemed to satisfy requirements
Code gives no guidance on how long
a structure should remain in service
Lacks models for prediction of
deterioration of structures
No metrics to define if a durable
design is achieved
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Service Life Design Basics

Establishing

Life Expectancy

Identifying

Environmental Exposure Conditions

Deterioration Mechanisms
Material Resistance to Deterioration
Establishing

Mathematical Modeling
Parameters to Predict Deterioration
Setting Acceptable Damage Limits
11

Life Expectancy
AASHTO

LRFD Bridge Design

Specifications Section 1.2
Design Life Period of time on which
the statistical derivation of transient
loads is based 75 years for these
Specifications.
Service Life The period of time that
the bridge is expected to be in
operation.
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Whats a Reasonable Service Life?

50,

75, 100, 150 years, more?

Expected

Service Life is based on

Owners desires and expectations

Actual

Service Life will depend on

Exposure conditions of structure

Quality of materials, design and
construction
Level of maintenance performed
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Indicative Values for

Design Service Life fib Bulletin 34
Design Service
Life, yrs
10

Examples
Temporary Structures
(Structures or parts of structures that can be dismantled with a
view to being re-used are not to be considered temporary)

10-25
15-30
50
100

Replaceable structure parts, e.g.,

gantry girders, bearings
Agricultural and similar structures
Buildings and other common
structures
Monumental buildings, bridges, and
other civil engineering structures
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Service Life Designed Structures

Great

yrs)

Belt Bridge, Denmark (100

15

Service Life Designed Structures

Confederation

yrs)

Bridge, Canada (100

16

Service Life Designed Structures

San

Francisco Oakland Bay Bridge

(150 yrs)

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What About These Structures?

Representing

the majority of the

600,000+ Bridges in the US

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Exposure Conditions

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Site Exposure Conditions

Aggressivity

of Environment

Sea water
De-icing agents
Chemical attack
Temperature

/ Humidity

Freeze / thaw cycles

Wet / Dry cycles
Tropical (every +10 C doubles rate of
corrosion)
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Member Exposure Conditions

Marine

Submerged, tidal, splash, atmospheric

zones
Geographic

Orientation

N-S-E-W, seaward, landward

Surface

Orientation

Ponding, condensation, protection from

wetting, corners
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Exposure Classes
European Standard EN-206-1
Class

Description

X0

No Risk of Corrosion or Attack

XC1-XC4

Corrosion Induced by Carbonation

XD1-XD3

Corrosion induced by chlorides other

than from sea water
Corrosion induced by chlorides from
sea water
Freeze/thaw attack with or without deicing agents
Chemical attack

XS1-XS3
XF1-XF4
XA1-XA3

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Deterioration
Nothing

lasts forever

Every

material deteriorates at a
unique rate

Deterioration

rate is dependent on
exposure conditions
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Deterioration Mechanisms
Reinforced

Concrete

Chloride Induced Corrosion

(Seawater, de-icing salts)
Carbonation Induced Corrosion
(Normal CO2 from atmosphere)

24

Deterioration Mechanisms
Structural

Steel

Corrosion after Breakdown of Protective

Coating Systems

25

Protection Systems
Materials

Own Ability to Resist

Deterioration Concrete Quality
(Permeability) and Cover

Protective

Coatings

Membranes

& Overlays
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Deterioration Models

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Chloride Induced Corrosion Models

Ficks 2nd Law Models Time to Initiate Corrosion in

Uncracked Concrete
Ccrit

C( x

cov, t)

cov x

Co + ( Cs , x Co) 1 erf

2
D

t
app , C

C(x,t)

Chloride concentration at depth & time

erf

Mathematical error function

Ccrit

Critical chloride content (to initiate corrosion)

Co

Initial chloride content of the concrete

Cs,x

Chloride concentration at surface or depth x

cov

Depth of concrete cover

Dapp,C

Apparent coefficient of chloride diffusion in

concrete (permeability)
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Deterioration Models / Limit States

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Limit States Reinforced Concrete

1 - Depassivation No damage to
reinforcing / end of initiation phase,
corrosion begins
2 - Cracking Initial expansion of
corrosion by-products
3 - Spalling Corrosion by-products cause
loss of concrete cover and bond to
reinforcing steel
4 - Collapse Loss of reinforcing steel
cross section from corrosion

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Limit States
Current

practice for new structures is

Depassivation phase
fib Commission 5 established task
groups on June 18-19, 2009 in
London to better define:
Critical Chloride Content to cause
reinforcing steel depassivation
Measurable limits for cracking, spalling,
and loss of section
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Structural vs. Durability Issues

Design
Design Work Item

Structural Issues

Durability Issues

Identify Owners
Requirements & Desires

Functionality, Capacity (#
lanes), Appearance

Target Service Life

Identify Externally Applied

Actions

Loads (Self weight, Live

Loads, Wind, Thermal,
Seismic, etc.) and Load
Factors

Environmental actions
(chloride attack, carbonation,
freeze-thaw, chemical attack,
etc.)

Select Materials

Concrete Strength, Steel Yield

& Ductility and Resistance
Factors

Chloride diffusion coefficient

in concrete, reinforcing steel
type & coating (plain, epoxy
coated, stainless)

Determine Dimensions

Spans, Component cross

sections

Cover dimensions

Summarize Results

Construction Plans &

Specifications, Engineers
Cost Estimate, Calculation
Books

Durability Report (initiate

Birth Certificate),
Construction Specifications
(new Diffusion Coefficient
testing), Engineers Cost
Estimate
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What is Needed to Implement a

Service Life Design Process?

Further Development of
Deterioration Models (especially for
Propagation phase)
Limit States for Acceptable Damage (including
critical chloride content)

Creating Design Examples / Workshops

Transfer Concrete Service Life Design
Process to Steel and Other Materials
Get the Attention of FHWA & AASHTO
State Bridge Engineers

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Birth Certificate
fib

New Model Code chapter 2, will

define a Birth Certificate.
A document, report or technical file (depending on the size and
complexity of the structure concerned) containing engineering
information formally defining the form and the condition of the structure
after construction. The document / report should provide specific details
on parameters important to the durability and service life of the structure
concerned (e.g. cover to reinforcement, concrete permeability,
environmental conditions, quality of workmanship achieved etc) and the
basis upon which future knowledge of through-life performance should
be recorded. This framework should provide a means of comparing
actual behaviour / performance with that anticipated at the time of design
of the structure. The document / report should facilitate ongoing
(through-life) evaluation of the service life which is likely to be achieved
by the structure.

34

Birth Certificate Purpose

Contains

engineering information
defining form and condition of
structure at end of construction

Documents

specific parameters
affecting durability of structure

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Structural vs. Durability Issues

Construction
Construction Work Item

Structural Issues

Durability Issues

Perform, Monitor & Inspect

Work

Verify dimensions, test &

document material strength
properties

Verify and map cover, test &

document actual material
durability properties (chloride
diffusion coefficient, etc.)

Track Variances

Accept / Accept with cost

adjustment for deficiencies /
Reject

Accept / Accept with cost

adjustment for deficiencies /
Reject

Summarize Results

As-Built Plans, Load Rating

Durability Rating, update

Birth Certificate

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Birth Certificate Purpose

(continued)
Compares

actual behavior /
performance with that anticipated
during design

Facilitates

on-going (through-life)
evaluation of remaining service life

37

Structural vs. Durability Issues

In-Service Use
Work Item

Structural Issues

Durability Issues

Routine Visual Inspections

(Biennial required by law)

To detect obvious defects

with minimal testing

Same as structural

In-Depth Monitoring (every 710 years)

Reactive Identify problem

areas as they occur (Concrete
Cracks & Spalls, Reinforcing
Corrosion, Joint and Bearing
failure)

Proactive Testing to monitor

in-service conditions (chloride
diffusion coefficient, chloride
profiles, chloride surface
concentration)

Assessment

Change in Use/Loading or
After Significant Event
(Earthquake, Hurricane,
Flood, Fire, Explosion,
Truck/Ship Impact)

Assess Remaining Service Life

of Components

Rehabilitation/Intervention

Replace/Repair/Strengthen
damaged structural
components

Perform Corrosion Surveys Add Corrosion Protection

Systems (Galvanic, Cathodic
Protection, or Electrochemical
Systems)

Dismantling

Demolish & Remove Waste

Recycle & Re-Use Materials

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Birth Certificate
Table of Contents
1)

Identification of Asset

Description & Identification of Structure

General Plan & Typical Section Drawings
Design Parameters / Target Service Life
2)

Environmental Exposure
Conditions

3)

Deterioration Models
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Birth Certificate
Table of Contents (continued)
4)

Summary of Individual Structure

Components
Mapping of:
Exposure

Classes/Severities
Deterioration Models
Mean Material Properties
Mean Cover Dimensions
Expected Service Life (Target & Remaining)

40

Birth Certificate
Table of Contents (continued)
5)

Summary of Ancillary
(Replaceable) Components
Mapping & Documentation (similar to
Structural Components) for:
Bearings
Expansion

Joints
Protective Membrane Systems

41

Birth Certificate
Table of Contents (continued)
6)

In-Service Inspection

Routine & Special Maintenance Schedule

Schedule of Inspections
Routine

Visual (Biennial)
In-Depth Monitoring and Sampling (7-10
years)

Special Test Method Requirements

7)

Dismantling Plan
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Example Birth Certificate

43

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Birth Certificate Next Steps

Determine

Guidelines for:

Type and number of tests of material

durability properties
Type and extents of as constructed
concrete cover measurements
Develop

templates for additional

Deterioration Models for the Example
Birth Certificate (Carbonation)
49

Birth Certificate Next Steps

Develop

criteria for deterioration

models for Ancillary Components
(Joints & Bearings)
Develop a suggested format for
Inspection & Maintenance Schedule
(similar to automobile maintenance
schedules)
Develop a template for a Dismantling
Plan
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Concluding Remarks

Service Life Design & Inventory

Management
Addresses the whole life of the structure
Requires a new proactive mindset for the
industry
Has huge potential for predicting the future
health, safety, and allocation of funding of our
infrastructure

Process in its Infancy

Better prediction tools need to be developed
But, we need to start somewhere
51

Questions?
Thank you

52