Application of High-Strength and Corrosion-Resistant ASTM A1035 Steel Reinforcing Bar in

Concrete High-Rise Construction

S. Faza1, J. Kwok1 and O. Salah2

1
MMFX Technologies Corporation, Irvine, California, U.S.A, Email: salem.faza@mmfx.com
2
Zamil Holding Group, Al Khobar, Saudi Arabia, Email: Osamas@zamilcd.com.sa

Abstract
Concrete reinforcing steel congestion in high-rise structures is a major concern to design engineers. Congestion of the
reinforcing steel decreases the efficiency of construction and adds greatly to the cost of construction of high-rise
structures. MMFX Microcomposite steel bars (MMFX 2), conforming to ASTM A1035 specification, have
high-strength properties that can be utilized to combat this problem. In addition, ASTM A1035 steel bar’s distinct
microstructure technology provides an answer for the worldwide corrosion problem. The technology that gives ASTM
A1035 steel bar its mechanical properties also make it very corrosion resistant. Independent tests show that the chloride
threshold of this uncoated steel is 5 to 6 times greater than that of conventional A615 steel bars and 1.75 greater than
2101 solid stainless steel bars. This paper presents the economical analysis done on the design and construction of
different high-rise structures and make recommendations to designers on where cost savings can be realized. The use of
ASTM A1035 steel bar reduced the amount of steel in some areas salem.faza@mmfx.com
by up to 40% while providing johnny.kwok@mmfx.com
a reduction in the
installed
Salem cost of the material by 15-25% in the highly congested areas.
Faza
Dr. Faza has more than 20 years experience in the concrete industry specializing in conventional and advanced reinforcing
Keywords:
products. HeHigh-Strength Steel, Corrosion
has been involved Resistance, ASTM
in the development A1035,
and code High-Riseof
acceptance Construction
advanced reinforcing products at the national
and international levels. Dr. Faza has been a member of the American Concrete Institute for the past 15 years, and served
as co-chairman of the ACI 440-H and 440-K subcommittees on
Introduction advanced
time, etc. reinforcing materials and currently serves on
the ACIOne439 of
steelthe
reinforcing committee. He also
major issues currently facing theserves on the American Society of Testing Materials and the American
Society of Civil Engineering committees. Through
concrete construction industry is the congestion of his involvement with concrete reinforcements,
The inherent corrosion resistance he planned,property
supervised,
of
and coordinated all phases of application engineering
reinforcing steel in structural components. Rebar including ASTM A1035 reinforcing steel would also improveInthe
research programs at over 20 institutions worldwide. his
role as the President
congestion complicatesof Middle East Operations
steel placement, for MMFX
hinders concreteTechnologies
long-termCorporation,
durability ofDr.
theFaza has beenIfinstrumental
structure. in the
water penetrates
development and acceptance of the newest ASTM
placement, and as a result leads to improper consolidation reinforcing bar specification for the high strength steel (ASTM
the waterproofing membrane or if the reinforced concrete A1035)
in
ofthe Middlearound
concrete East. Dr. Faza affecting
rebar, is currently
thecoordinating
integrity ofcode
the development for concrete
strucural member designs
is exposed towith MMFX
water, steelcan
the water reinforc-
reach
ing bars. Dr. Faza received his Ph.D. from West Virginia University
structure. in Advanced
the reinforcing Composite
through Applications
the anticipated in Construction
micro-cracks that
with emphasis on rebars for concrete application, design, and analysis. He haswith
are inevitable published overASTM
concrete. 30 papers related
A1035 rebartoprovides
concrete
reinforcement
Anotherandmajorconstruction and hasfacing
issue currently been athe
reviewer
concretefor leading
muchengineering technicalunder
better performance journals.
these conditions.
construction industry is the corrosion of steel reinforcing
Johnny Kwok
in concrete members subjected to corrosive environment. ASTM A1035 Steel Reinforcement
Mr.
Corrosionhas
Kwok ofmore
steelthan 13 years ofleads
reinforcing structural design experience
to reduction in in California. He received
The strength of ASTMhis undergraduate
A1035 steeland graduate
rebars far
degrees from the University of California,
strength of the concrete member, and causes the Berkeley, and Mastersurpasses conventional steel. The high-strengthat
of Business Administration from the Anderson School
UCLA. Over hisofcareer,
deterioration the Mr. Kwok has completed
surrounding concrete, structural
further design for over $1 Billion
corrosion-resistant steelworth
bars of
arebuilding
producedstructures,
in 12 andinclud-
18m
ing regional mall expansion, new airport terminal,
damaging the concrete member. Repair and maintenance high-rise structures,
(40 and 60 ft) stock lengths. Alternatively,damping
as well as seismic retrofit using high-tech longer
devices. His expertise
cost is enormous has been
to address the in seismic issue.
corrosion design of structures,lengths
and specialized in reinforced
can be produced concrete
by using and structural
mechanical splices steel
that
design. Mr. Kwok serves as the chief structural engineer at MMFX, develop the full strength of the reinforcing bars. Stockfirms
presenting and educating structural engineering 12
on the specialized
Proposed rebar product, assisting engineers with designand
Resolution and18technical
m (40 support,
and 60 and
ft) working closely with
length material building
is generally
officialsUtilizing
and codethe authorities
higher toyield
approve the useofofrebar
strength MMFX in rebars in construction
available in bar projects
sizes [#10both(#3)
in thethrough
U.S. and#36
overseas.
(#11)].
designing various structural components, such as mat Stock material for #10 (#3) through #15 (#5) bars are
foundations, shearwalls, etc., the amount of reinforcing available in coils commonly used by fabricators for
steel required would be reduced and thus relieving the fabrication of ties and spirals. Bar sizes #43 (#14) and
rebar congestion. Reduced congestion facilitates concrete #57 (#18) are generally available, but these bar sizes are
consolidation around the rebar, and results in safer not usually kept in fabricator’s inventory.
structures.
Material Composition
Besides the ease of placement of rebar and concrete, One of the unique features of the ASTM A1035
the use of higher strength steel reinforcing can be an steel rebar is the chemical composition. The maximum
economical method of construction, by reducing the total chemical constituent requirements of the ASTM A1035
tonnage of steel reinforcing, the placement labor, and reinforcing bars are illustrated in Table 1:

CTBUH 8th World Congress 2008 

Application of High-Strength and Corrosion-Resistant ASTM A1035 Steel Reinforcing Bar in
Concrete High-Rise Construction

S. Faza1, J. Kwok1 and O. Salah2

1
MMFX Technologies Corporation, Irvine, California, U.S.A, Email: salem.faza@mmfx.com
2
Zamil Holding Group, Al Khobar, Saudi Arabia, Email: Osamas@zamilcd.com.sa

Abstract
Concrete reinforcing steel congestion in high-rise structures is a major concern to design engineers. Congestion of the
reinforcing steel decreases the efficiency of construction and adds greatly to the cost of construction of high-rise
structures. MMFX Microcomposite steel bars (MMFX 2), conforming to ASTM A1035 specification, have
high-strength properties that can be utilized to combat this problem. In addition, ASTM A1035 steel bar’s distinct
microstructure technology provides an answer for the worldwide corrosion problem. The technology that gives ASTM
A1035 steel bar its mechanical properties also make it very corrosion resistant. Independent tests show that the chloride
threshold of this uncoated steel is 5 to 6 times greater than that of conventional A615 steel bars and 1.75 greater than
2101 solid stainless steel bars. This paper presents the economical analysis done on the design and construction of
different high-rise structures and make recommendations to designers on where cost savings can be realized. The use of
ASTM A1035 steel bar reduced the amount of steel in some areas by up to 40% while providing a reduction in the
installed cost of the material by 15-25% in the highly congested areas.

Keywords: High-Strength Steel, Corrosion Resistance, ASTM A1035, High-Rise Construction

Introduction time, etc.

One of the major issues currently facing the
concrete construction industry is the congestion of
reinforcing steel in structural components. Rebar
congestion complicates steel placement, hinders concrete
placement, and as a result leads to improper consolidation
of concrete around rebar, affecting the integrity of the
structure.
Another major issue currently facing the concrete
construction industry is the corrosion of steel reinforcing
in concrete members subjected to corrosive environment.
Corrosion of steel reinforcing leads to reduction in
strength of the concrete member, and causes the
deterioration of the surrounding concrete, further
damaging the concrete member. Repair and maintenance
cost is enormous to address the corrosion issue.
Proposed Resolution
Utilizing the higher yield strength of rebar in
designing various structural components, such as mat
foundations, shearwalls, etc., the amount of reinforcing
steel required would be reduced and thus relieving the
rebar congestion. Reduced congestion facilitates concrete
consolidation around the rebar, and results in safer
structures.
Besides the ease of placement of rebar and concrete,
the use of higher strength steel reinforcing can be an
economical method of construction, by reducing the total
tonnage of steel reinforcing, the placement labor, and
The inherent corrosion resistance property of
ASTM A1035 reinforcing steel would also improve the
long-term durability of the structure. If water penetrates
the waterproofing membrane or if the reinforced concrete
strucural member is exposed to water, the water can reach
the reinforcing through the anticipated micro-cracks that
are inevitable with concrete. ASTM A1035 rebar provides
much better performance under these conditions.
ASTM A1035 Steel Reinforcement
The strength of ASTM A1035 steel rebars far
surpasses conventional steel. The high-strength
corrosion-resistant steel bars are produced in 12 and 18m
(40 and 60 ft) stock lengths. Alternatively, longer
lengths can be produced by using mechanical splices that
develop the full strength of the reinforcing bars. Stock 12
and 18 m (40 and 60 ft) length material is generally
available in bar sizes [#10 (#3) through #36 (#11)].
Stock material for #10 (#3) through #15 (#5) bars are
available in coils commonly used by fabricators for
fabrication of ties and spirals. Bar sizes #43 (#14) and
#57 (#18) are generally available, but these bar sizes are
not usually kept in fabricator’s inventory.
Material Composition
One of the unique features of the ASTM A1035
steel rebar is the chemical composition. The maximum
chemical constituent requirements of the ASTM A1035
reinforcing bars are illustrated in Table 1:

 CTBUH 8th World Congress 2008

Table 1. Max. Chemical Constituents (Weight %). Table 2. Tensile properties of ASTM A1035 high strength steel bars.
*Maximum unless range indicated. Property GRADE GRADE
ASTM A1035 100 120
Maximum Typical Tensile strength, 1030 1030
Element min, MPa [psi] [150 [150 000]
Amount * MMFX 2
000]
Carbon 0.15% 0.08% Yield strength 690 830
Chromium 8 to 10.9% 9% (0.2 % offset), min, [100[120 000]
Manganese 1.5% 0.5% MPa [psi] 000]
Nitrogen 0.05% Stress 550 620
Phosphorus 0.035% corresponding to an [80 000]
[90 000]
Sulfur 0.045% extension under
Silicon 0.50% load of 0.0035
mm/mm. (0.0035
Tensile Properties in/in), min, MPa
The ASTM A1035/A1035M steel bars are of two [psi]
minimum yield strength levels: namely, 100 000 psi [690 Elongation in 203.2 mm [8 in.] min. %:
MPa], and 120 000 [830 MPa] designated as Grade 100 #10 through #36 7 7
[690] and Grade 120 [830], respectively. The yield [#3 through #11]
strength is determined by the offset method (0.2 % #43, #57 [#14, 6 ---
offset), described in Test Methods and Definitions ASTM #18]
A370 (ASTM 2004). In addition, the stress corresponding
to a tensile strain of 0.0035 shall be a minimum of 550 The design of concrete members reinforced with
MPa [80 000 psi], and a minimum of 620 MPa [90 000 ASTM A1035 steel rebars for flexure is analogous to the
psi] for Grade 100 and Grade 120 respectively. The design of concrete reinforced with conventional steel bars.
mechanical properties are summarized in Table 2. Experimental data of concrete members reinforced with
ASTM A1035 steel bars show that flexural capacity can
Corrosion Properties be calculated based on similar assumptions for members
Many highly credible institutions and government reinforced with ASTM A615 carbon steel rebars, taking
agencies have tested the corrosion resistance of ASTM into account the higher strength of the ASTM A1035 steel
A1035 steel bars. Substantial documented test results bars.
have been published to validate the corrosion resistance
of this innovative steel product. The high-corrosion Designers need to be aware that typical design
resistance provides increased service life to the steel standards limit the design strength to 550 MPa [80,000
before its structural carrying capacity has dissipated psi], and that the use of deformed reinforcing bar with a
leading to reduced serviceability of reinforced concrete material specified yield strength fy exceeding 420 MPa
structures, damage to structural load carrying capacity or [60,000 psi] is permitted, providing fy is the stress
loss of aesthetic appeal. ASTM A1035 steel bars’ corresponding to a strain of 0.35%. Based on the
corrosion resistance is 5 to 6 times better than the experimental results and the analysis conducted, the
corrosion resistance of conventional carbon steel (ASTM design of a concrete section reinforced with ASTM
A615) as measured by its critical chloride threshold level, A1035 steel bars can be simplified by using the ACI 318
CCTL (Clemena, G.G. 2004). design philosophy and 690 MPa [100,000 psi] in tension,
while limiting the stresses in compression up to 550 MPa
Flexural Tension Applications [80,000 psi]. However, well-confined concrete, such as
Practical application of ASTM A1035 steel rebars that used in seismic-resisting columns and shear walls,
to high-rise construction includes, but is not limited to, has a compressive strain capacity much greater than that
tension piles, mat foundations, shearwalls and moment of unconfined concrete. So, the 80,000 psi and 0.35
frames, etc. These structural components designed with percent limits in steel compression strength may be
the higher yield strength property of ASTM A1035 steel unnecessary for well-confined concrete.
rebars have been demonstrated to be cost effective,
improve constructability, and shorten construction
schedules. An example of this type of design and
construction is illustrated in figures 1 and 2 for a Miami,
FL High-Rise tower.

CTBUH 8th World Congress 2008 


Figure 1. The use of ASTM A1035 in Flexural Design in a Miami
High-Rise Structure
Calculations involved in control of cracking should
be made for the service load level. Research have shown
that, in spite of service load steel stresses as high as
60,000 psi, the width of individual cracks can be held
down to hair-line size by proper distribution of the bars
(Malhas, F. 2002, El-Hasha, R. and Rizkalla, S. 2002).
The strength characteristics of high quality concretes
along with the high corrosion resistance properties of the
high strength steel will complement the structural
properties of the ASTM A1035 steel bars, thus facilitating
design development of attractive and economical
structures.
Figure 2: ASTM A1035 in Mat Foundation
Transverse Reinforcement Applications
One of the applications that high-strength
reinforcing steel achieved code recognition and market
acceptance is for use as transverse reinforcement in
columns and comparable vertical elements. There are
indications worldwide that increased design requirements
for transverse reinforcing steel especially in concrete
columns and piles, are either exceeding the practical
capacity of mild steel reinforcing bars, or are causing
such a great amount of steel congestion that correct
placement and consolidation of concrete is becoming
complex.
There are further indications that this burden is
adversely affecting the market for such reinforced
concrete structures by making them prohibitively more
 CTBUH 8th World Congress 2008
expensive. As a result, alternative members such as
structural steel rolled sections have replaced reinforced
concrete as the material of choice. It appears that in
some regions, design engineers are seriously questioning
the ability of reinforced concrete members utilizing mild
steel reinforcement to perform with structural integrity
under certain types of anticipated loading conditions. In
one western state in the United States, prestressed
concrete piles are no longer doable under the current code
restraints.
As a result, the newly published American
Concrete Institute, ACI, 318-05 building code includes a
new provision for allowing the use of higher design
stresses for spiral transverse reinforcement in section
10.9.3 of the building code.
The American Concrete Institute’s ACI 318-05
building code commentary provides the following
explanation for the acceptance of the use of the high
strength steel bars with yield strength of 100,000 psi for
spiral reinforcement: "Confinement reinforcement often
creates congestion in reinforced concrete structures.
Research shows that 690 MPa (100,000 psi) yield
strength reinforcement can be used for confinement (ACI,
2005). This will reduce congestion, thereby making
structures safer, because concrete can be consolidated
more easily, and will make structures more economical".
Furthermore, the upcoming ACI 318-08 building
code extends the use of ASTM 1035 steel in transverse
reinforcement ties for confinement purpose, for structural
components subjected to high seismic load as illustrated
by recently designed and constructed Escala’s high-rise in
Seattle, Washington shown in Figure 3.
Figure 3: Escala’s concrete frame with 100 ksi confinement steel (Photo
courtesy CKPS)
Structures Exposed to Corrosive Environment
The corrosion-resistant ASTM A1035 steel rebars
are also ideal for structural members and systems
exposed or in direct contact with corrosive environment,
such as humid atmosphere, high foundation water table,
and corrosive soil condition. Possible application would
be in foundation piles, foundation systems, marine
structures, exposed balconies, etc. ASTM A1035 was
used in the construction of the California Academy of
Sciences exhibition, education and research center in the
foundation and aquarium tanks as shown in Figure 4.
Figure 4: California Academy of Sciences – Exhibition, Education and
Research Center – San Francisco, CA Foundation and Aquarium
Tank
Figure 5. Side by side ASTM A1035 (MMFX) vs. ASTM A615.
Practical example 1: Parking structure in Las Vegas,
NV (mat foundation application)
The proposed project is located in Las Vegas,
Nevada, U.S.A. The structure consists of 12 levels of
steel parking decks, supported on a 5’-0” thick concrete
mat. The original design was completed using ASTM
A615 Grade 60. A preliminary redesign was performed
using ASTM A1035 steel bars using 690 MPa [100 ksi]
design to provide the equivalent steel strength in the mat.
The redesign led to significant savings in total weight of
reinforcing, pieces of steel to be placed, as well as overall
installed cost. A summary of the potential savings is
listed in the Table 3 below:

Table 3. Potential project savings (A1035 vs. A615) – Mat Foundation.

Structural systems reinforced with ASTM A1035
steel rebars have shown to provide extended service lives Bar Type Cost ($) Weight (tons) Placing
of 75 to 100 years, depending on the severity of the (pieces)
exposure. A615 $1,793,572 1,121 13,478
Gr.420 [60
Lowest Construction System ksi]
The effectiveness of reinforcement in strengthening A1035 690 $1,521,533 644 9,765
a concrete member is generally almost proportional to the MPa
product of bar area and yield strength, Asfy. The [100ksi] w/
couplers
economies of high strength steels may therefore be
Savings $272,039 477 3,713
estimated in terms of costs per ton per psi yield strength. 15% 43% 28%
Relative costs of reinforced concrete structures depend on
several factors in addition to the cost of reinforcing steel.
Further analysis was performed to include the use
The reduction of steel area which accompanies an
of high-strength mechanical couplers in reinforcing splice
increase in fy often facilitates concrete placement by
locations. The purpose of the exercise was to illustrate
eliminating steel congestion.
further potential savings by eliminating long reinforcing
splices and replacing with mechanical couplers. Again,
The technology behind ASTM A1035 steel bars
the result of the analysis indicated further savings as
can change the way high-rise buildings are designed.
illustrated in Table 4 below:
ASTM A1035 steel products provide the designer with
higher grade steel along with the corrosion-resistant
Table 4. Potential project savings (A1035 w/ couplers vs. A615) – Mat
properties, at a lower overall cost. The added strength of
Foundation.
ASTM A1035 steel rebars results in an incremental
decrease in the amount of conventional steel necessary to Bar type Cost ($) Weight (tons)
accomplish the same task. High-rise structures can be A615 Grade 420 $2,709,290 1,500
designed with less congestion without adding additional [60]
concrete cover. By specifying ASTM A1035 steel rebar, A1035 690 MPa $2,160,540 1,097
[100ksi]
the high-rise owner will experience upfront cost savings,
Savings $548,750 403
as well as lower life cycle costs.
20% 27%
Projects using ASTM A1035 steel rebars can be
completed with up to 40% less steel resulting in less Practical example 2: High-rise condominium tower in
congestion and up to 50% lower labor costs (Fig. 5). Las Vegas, NV (shearwall application)
Stronger, more corrosion resistant, and with faster The proposed project is a 50 story tall
construction build times, ASTM A1035 steel bar is truly a condominium tower in Las Vegas, Nevada. The building
key component of the lowest cost construction system. system consists of post-tensioned concrete flat plates,

CTBUH 8th World Congress 2008 

concrete shearwalls, and mat foundation. The high aspect
ratio of the building causes the flexural reinforcing, also
known as jamb reinforcing, to be very substantial with
Grade 420 [60] reinforcing. Due to the high flexural
reinforcing and congestion in the shear wall boundary
zones, an alternate reinforcing scheme was considered
using ASTM A1035 steel reinforcing. Shear walls of the
tower were redesigned using ASTM A1035 steel from
foundation through the roof level. The use of ASTM
A1035 in the flexural reinforcing of the tall shear walls
effectively reduced the amount of congestion in the shear
wall boundary zones. The following Table 5 illustrates
the savings realized:
Table 5. Potential project savings (A1035 vs. A615 Grade 60) –
Shearwall Jamb Reinforcing.
Bar Type Cost ($) Weight (tons) Placing
(pieces)
A615 Gr. $1,793,572 1,121 13,478
420 [60 ksi]
A1035 690 $1,570,622 714 10,874
MPa
[100ksi]
Savings $222,950 407 2,604
12% 36% 19%
The savings shown in the table only include the
effect of ASTM A1035 reinforcing substitution for
flexural reinforcing of the walls. With less flexural
reinforcing, the boundary zone transverse reinforcing ties
are also significantly reduced, leading to further
installation savings.
In addition, the mat foundation was also
redesigned using ASTM A1035 steel reinforcing to
reduce the amount of horizontal flexural reinforcing. To
further utilize the high strength property of ASTM A1035
steel bars, the total thickness of the mat foundation
system was reduced by 3 feet on average. As a result,
there is a total savings of more than 4,000 cubic yard of
concrete. In additional to the steel reinforcing savings,
there is significant reduction in excavation, dirt haul-out,
concrete pour back, as well as construction schedule.
Table 6 below summarizes the savings incurred on the
project by utilizing ASTM A1035 steel reinforcing:
As illustrated in the examples above, the use of
ASTM A1035 steel reinforcing is very effective in
reducing overall project cost. The above examples only
consider the effect of direct substitution of reinforcing.
However, there are other potential savings areas including
less reinforcing congestion, less placement difficulties,
less plasticizer in concrete mix, more effective concrete
pour, and ultimately overall project time and cost savings.
 CTBUH 8th World Congress 2008
Table 6. Potential project savings (A1035 vs. A615 Grade 60) – Mat
Foundation w/ Reduced Thickness.
Bar type Cost ($) Weight (tons)
A615 Grade $1,739,040 1,449
420 [60]
A1035 690 $1,695,050 1,097
MPa [100ksi]
Concrete $1,200,000 4,000 cubic yard
Savings Estimated
Total $1,243,990 (plus 2 weeks saving in
Foundation excavation time)
Savings
Conclusions
Concrete reinforcing steel congestion in high-rise
structures can be addresses utilizing the high-strength
corrosion-resistance MMFX 2 steel bars produced in
accordance with the ASTM A1035 specification. It is
apparent that the use of ASTM A1035 steel bar is
extremely effective in reducing the total weight of steel
for the project, providing flexibility in structural design,
and at the same time achieving tremendous time and
labor savings.
References
ACI Committee 318, 2005. Building Code Requirements for
Structural Concrete (ACI 318- 05) and Commentary (ACI 318R-05).
Farmington Hills: American Concrete Institute.
ASTM A1035, 2007 – “Standard Specification for Deformed and
Plain, Low-carbon, Chromium, Steel Bars for Concrete
Reinforcement”, ASTM International, 100 Barr Harbor Drive, PO Box
C700, West Conshohocken, PA 19428-2959, United States.
ASTM A370, 2004 – “Test Methods and Definitions for Mechanical
Testing of Steel Products”, ASTM International, 100 Barr Harbor
Drive, PO Box C700, West Conshohocken, PA 19428-2959, United
States.
EL-HACHA, R. and RIZKALLA, S. 2002. Fundamental Material
Properties of MMFX Steel Rebars. Retrieved February 5, 2004, from
the MMFX Technologies Corporation Web site:
MALHAS, F.A. 2002. Preliminary Experimental Investigation of the
Flexural Behavior of Reinforced Concrete Beams Using MMFX
Steel. Retrieved February 5, 2004, from the MMFX Steel Corporation
of America Web site
CLEMENEA, G. and VIRMANI, P. Comparing the Chloride
Resistance of Reinforcing Bars”, Concrete International, November
2004, Farmington Hills, American Concrete Institute.
S.K. GHOSH 2006. Application of ASTM A1035 MMFX Steel
Reinforcement in Building Application: An Appraisal.