Abstract

Pack rust or crevice corrosion is a type of localized corrosion. When a metal is in contact with a metal, or even non-metal, the metal starts to corrode, and rust starts to pack in between the surfaces. When significant development of pack rust occurs, it can cause overstressing of bolts and rivets causing them to fail, and it can bend connecting plates and member elements thus reducing their buckling capacity. Thus it is important to mitigate the formation and growth of pack rust in bridges. This study was conducted to determine if pack rust occurs frequently and thereby may pose a problem in the state of Indiana. The study is divided into three primary tasks. The first part of the study involves understanding the parameters involved in the initiation process of crevice corrosion and post-initiation crevice corrosion process. The second part of the study involves reviewing existing mitigation strategies and repair procedures used by state DOTs. The third part of the study involves identifying steel bridges with pack rust in Indiana. Analyses were performed on the data collected from Indiana bridges that have pack rust. This involved finding the components and members of bridges which are most affected by pack rust and finding parameters which influence the formation of pack rust. Pack rust in the steel bridges were identified using the INDOT inspection reports available through BIAS system. The study revealed that good maintenance practices helped in reducing pack rust formation. The study identified locations on steel bridges which have a high probability towards pack rust formation. A mitigating strategy possessing qualities which can show promising results is identified.

Highlights

  • Corrosion is a major problem in the infrastructure industry, costing millions of dollars every year for maintenance, repair, or replacement

  • The members with the highest percentage of pack rust occurrence are gusset plates and hinge-pin connections: pack rust occurred in both of these components in more than 90% of the bridges with such details

  • Further study should be done to investigate the effectiveness of stripe coating and the need to modify the number of stripe coats utilized

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Summary

Introduction

Corrosion is a major problem in the infrastructure industry, costing millions of dollars every year for maintenance, repair, or replacement. Very few studies have been conducted to study the influence of pack rust (crevice corrosion) on steel bridges. When steel elements of a member are unprotected and in contact with another metal, or even non-metal, the steel usually begins to corrode, and rust (iron oxide) starts to develop, or pack in, between the surfaces. Pack rust is not visible until rust product starts deforming the adjoining members and elements. It can cause overstressing of bolts and rivets, and unchecked rust growth may result in bolt and rivet failure. Crevice corrosion is often not visible until it becomes very severe, and can lead to serious problems

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