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.