15 Durability and

16 Fire Resistance

Dr S R Satish Kumar, IIT Madras

Metal Connection

Electrolyte

Mechanism of corrosion as a
miniature battery
Anode
Drop of water

C
Cathode
Metal bar

Mechanism of Corrosion in steel

Methods of prevention corrosion - Simple

procedures

Detailing to enhance air

movement between
joints

Simple orientation of members

Simple rule:
Eliminate the electrolyte
Avoid simultaneous
presence of water and oxygen
3

Is Corrosion a real Problem?

Indian designers feel that steel corrodes most in
India. Is it true?
Steel corrodes all over the world! But they are
better managed in the western countries!
Excellent protective coatings which retain their
life even up to 20 years are available!
Corrosion-where does it matter? Normal inland
there is no problem! Exposed conditions
ofcourse do need attention.
Corrosion is no more a disincentive for not using
steel in housing sector!

SECTION 15 DURABILITY
15.1
General
15.2
Requirements for Durability
Shape, Size, Orientation of Members, Connections and
Details
Exposure Condition (Table 15.1)
Corrosion protection methods
Surface protection

Protective coating requirements (Table 15.2)

Special steel
Dr S R Satish Kumar, IIT Madras

TABLE 15.1 ENVIRONMENTAL EXPOSURE CONDITIONS

Environmental
Classifications
Mild

Moderate

Severe

Very severe

Extreme
Dr S R Satish Kumar, IIT Madras

Exposure conditions
Surfaces normally protected against exposure to weather
or aggressive condition as in interior of buildings, except
when located in coastal areas
Structures steel surfaces exposed to
i) condensation and rain
ii) continuously under water
iii) non-aggressive soil/groundwater
iv) sheltered from saturated salt air in coastal areas
Structural steel surfaces exposed to
i) severe frequent rain
ii) alternate wetting and drying
iii) severe condensation
iv) completely immersed in sea water
v) exposed to saturated salt air in coastal area
Structural steel surface exposed to
i) sea water spray
ii) corrosive fumes
iii) aggressive sub soil or ground water
Structural steel surfaces exposed to
i) tidal zones and splash zones in the sea
ii) aggressive liquid or solid chemicals

TABLE 15.2 PROTECTION GUIDE FOR STEEL WORK APPLICATION

(a) Coating System Desired Life in Different Environments (In Years)

Atmospheric
Condition

Coating
System
1

Coating
System
2

Normal
Inland
(Rural and Urban
areas)

12
years

18
years

*Polluted
Inland
(High
airborne
sulphur dioxide)

10
years

15
years

Normal
Coastal
(As normal inland
plus high airborne
salt levels)
Polluted
Coastal
(As polluted Inland
plus high airborne
salt levels)

10
years

12
years

8 years

10
years

Dr S R Satish Kumar, IIT Madras

Coating
System
3
20 years

12 years

20 years

10 years

Coating
System
4
About
20 years
About
18 years
About
20 years

About
15 years

Coating Coating
System system
5
6
About

Above

20
years

20
years

15-20
years

Above
20
years

About

Above

20
years

20
years

15 - 20
years

Above
20
years

TABLE 15.2 (b) Specification for Different Coating System

(i) Shop Applied Treatments
Coating
System

Surface
Preparation

Blast Clean

Blast Clean

Prefabrication
primer

Zinc
Phosphate
Epoxy 20 m

2 pack Zincrich Epoxy 20

m

Post
fabrication
primer

High-build Zinc
Phosphate
modified Alkyd
60 m

2 pack Zincrich Epoxy

20 m

Intermediate
coat

Top coat

Dr S R Satish Kumar, IIT Madras

3
Blast
Clean

4
Blast Clean

2 pack Zincrich Epoxy 20

m

Hot tip
Galvanise
85 m

2 pack Zincrich Epoxy 25

m

High-build
Zinc
Phosphate 25
m

5
Girt Blast

6
Blast Clean
Ethyl Zinc
Silicate 20
m

Sprayed Zinc Ethyl Zinc

Silicate 60
or Sprayed
Aluminium
m

2 pack Epoxy
Micaceous Iron
oxide

Sealer

Chlorinated
Rubber
Alkyd 35 m

2 pack Epoxy
Micaceous Iron
Oxide 85 m

Sealer

TABLE 15.2
(b) Specification for Different Coating System
(ii) Site Applied Treatments
Coating System
Surface
Preparation

Primer

Intermediate
Coat

Top Coat

1
As necessary

Touch in

High-build
Alkyd Finish
60m

Dr S R Satish Kumar, IIT Madras

2
As
necessary

Touch in
Modified
Alkyd
Micaceous
Iron Oxide
50 m
Modified
Alkyd
Micaceous
Iron Oxide
50 m

3
No site
treatment

4
As necessary

Touch In

High-build
Chlorinated
Rubber

5
No site
treatment

6
As necessary

Touch in

High-build
Micaceous Iron
Oxide
Chlorinated
Rubber
Micaceous 75 m

High-build Iron
Oxide
Chlorinated
Rubber75 m

FIRE PROTECTION
Positive points of steel as a
construction material under fire

Damage to strength of steel due to fire is

reversible in most of the cases
Using the principle if the member is straight
after the fire - the steel is O.K many of the
members could be salvaged.
Up to about 2150C steel retains its strength
In the case of concrete, at 2350C turns pink;
5900C turns red and irreversible damage after
6000C
Steel exposed to 6000C could be strengthened
and reused.
10

Typical fire loads and behaviour of steel

under fire
Examples of fire load in various structures
Type of steel structure
Kg wood / m2
School
15
Hospital
20
Hotel
25
Office
35
Departmental store
35
Textile mill show room
>200

11

Typical fire loads and behaviour of steel under fire

0C

1000

Furnace
temperature
Unprotected steel

500
Fire protected steel
temperature

0
30

60

90
Time (Minutes)
12

1.5

Coeff. of thermal
expansion (x 105)
1.0

0.5

Youngs modulus
ratio

Yield stress ratio

200

400

600

800

1000

Temperature 0C
Mechanical properties of steel at elevated
temperatures

13

Fire Engineering of steel structures

D
Hp =2D+B

Hp
=2D+3B-2t

High Hp / A
Value

Low Hp / A
Value

The section factor

concept

Hp =2D+2B

Hp
=2D+4B-2t

Some typical values of HP of

fire protected steel sections

14

Methods of fire protection

Spray protection
Board protection
Intumescent coatings

Concrete encasement?

15

SECTION 16 FIRE RESISTANCE

16.1

Requirements

16.2

Definitions

16.3

Fire Resistance Level

16.4

Period of Structural Adequacy (PSA)

16.5

Variation of Mechanical Properties of Steel with Temp.

16.6

Limiting Steel Temperature

16.7

Temperature Increase with Time in Protected Members

Dr S R Satish Kumar, IIT Madras

16

Fire Protection Criteria

period of structural adequacy (PSA) greater than or equal to the
required fire-resistance level (FRL) in minutes attained in the
standard fire test
FRL shall be prescribed by other standards depending on the use
of the structure and the time required to evacuate.
The period of structural adequacy (PSA) shall be determined using
one of the following methods:
(a) By calculation
(i) By determining the limiting temperature of the steel (Tl) in
accordance with 16.6 and then.
(ii) By determining the PSA as the time (in minutes) from the
start of the test (t) to the time at which the limiting steel
temperature is attained in accordance with 16.7 for protected
members and 16.8 for unprotected members.
(b) By direct application of a single test in accordance with 16.9 or
(c) Calculation of the temperature of the steel member by, using a
rational method of analysis confirmed by test data or by methods
available in Specialist literature.
Dr S R Satish Kumar, IIT Madras

17

16.5 Variation of Mechanical Properties of Steel with T

(a) Yield stress

905 T

f y (20)
690
f y (T )

1.2
1
0.8
0.6
0.4

(b) Modulus of elasticity

0.2
0

E (T )
T

1.0

E (20)
T
2000

ln 1100

6901

1000

T 53.5
Dr S R Satish Kumar, IIT Madras

200

400

600

800

1000

1200

0C T 600C

600C T 1000C
18

16.6 Limiting Steel Temperature

limiting steel temperature (Tl) in degree Celsius shall be calculated as

Tl= 905-690 rf
where
rf rf = ratio of the design action on the member under fire to the design
capacity of the member (Rd = Ru/m) at room temperature
Rd, R Rd , Ru = design and ultimate strength of the member at room
temperature
m = partial safety factor for strength
The design action under fire shall consider
a) The reduced bond likely under fire.
b) The effects of restraint to expansion of the elements during fire.

Dr S R Satish Kumar, IIT Madras

19

Temperature Increase with Time

Protected Members
16.7.1 The time (t) at which the limiting temperature (Tl) is attained shall
be determined by calculation on the basis of either
a suitable series of fire tests and regression analysis in accordance
with 16.7.2 or
from the results of a single test in accordance with 16.7.3.
Unprotected Members
calculate using the following equations.
a) Three-sided fire exposure condition

0.433T

t 5.2 0.0221T
k sm
0.213T

t 4.7 0.0263T
k sm

b) Four-sided fire exposure condition

where
t = time from the start of the test, in minutes
T = steel temperature, in degrees Celsius, 500oC T 750C
ksm = exposed surface area to mass ratio, 2103 mm2/kg ksm 35
103 mm2/kg
Dr S R Satish Kumar, IIT Madras

20

Fire resistant steels

Chemical composition of fire resistant steel

FRS
Mild
Steel

C
0.20
%
0.23
%

Mn
Si
1.50 0.50
%
%
1.50 0.40
%
%

S
0.04
0%
0.05
0%

P
0.04
0%
0.05
0%

Mo+Cr
1.00
%
-

Very cost effective compared to structural steel

FRS are available in India

Very popular and cost effective - Japanese

experience
21