In-situ testing and evaluation of rust layer stability in long lasting weathering steel bridges
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摘要: 基于耐候钢锈层形成和损伤机理，总结了耐候钢桥锈层检测及评价方法，并以中国首批3座免涂装耐候钢桥为工程依托，采用目测检查法和胶带黏附力测试法对典型构件的构造细节处锈层进行原位测试，通过对锈层稳定性的定性与定量分析，明确了结构型式、气候气象和环境条件等对耐候锈层形成的影响规律，分析了不同位置的表面锈层分布特点及稳定性差异，建立了长寿命耐候钢桥锈层稳定性技术状况评价模型，开展了全桥锈层稳定性技术状况评价，提出了锈层的针对性维护管养建议。研究结果表明：稳定锈层的形成受结构构造形式、水汽及光照等各种因素作用影响；耐候钢桥受日照充足的区域，其耐候锈层形成快、稳定性好；通风好且不易积水积尘区域的耐候锈层状况优于积水积尘区域和潮湿通风不畅区域；高湿热环境中的耐候钢桥，通风、日照条件好的区域，其耐候锈层形成快且稳定；耐候锈层稳定性技术状况可根据承重结构锈层稳定性状况、桥梁附属结构技术状况和桥位环境状况3类评价指标分为1~4级，综合评价眉县常兴二号桥、黄延高速隆坊跨线桥和西藏扎墨公路达国大桥锈层稳定性技术状况等级分别为2级、2级和3级；稳定可靠的耐候锈层是实现耐候钢桥长寿命设计和使用的技术保证之一。长寿命耐候钢桥锈层检测方法与评价指标可为桥梁构造设计及锈层维护管养提供依据，将推动长寿命耐候钢桥的工程应用。Abstract: Based on the formation and damage mechanism of rust layers on weathering steel, the methods for detecting and evaluating the rust layer of weathering steel bridges were summarized. By taking three uncoated weathering steel bridges in China as engineering projects, in-situ tests of rust layers on structural details of typical bridge components were conducted using the visual inspection method and tape adhesion testing method. Through qualitative and quantitative analyses of the rust layer stability, the influence pattern of structural forms, climate, and environmental conditions on the formation of rust layer on weathering steel was clarified. The distribution characteristics and stability differences of the surface rust layer at various locations were analyzed. A technical condition evaluation model for assessing the rust layer stability of long-lasting weathering steel bridges was established, and the technical conditions of rust layer stability across the whole bridge were evaluated, with targeted maintenance and management measures for rust layers provided. The results indicate that the formation of rust layers on weathering steel is affected by various factors, including structural form, moisture, and exposure to light. The weathering steel bridge areas with sufficient sunlight exposure develop rust layers more rapidly and with excellent stability. Bridge areas with good ventilation and minimal water and dust accumulation form better rust layers compared to areas prone to water accumulation, dust accumulation, and poor ventilation. For weathering steel bridges in high-humidity and hot environments, well-ventilated and sun-exposed areas exhibit rapid and stable rust layer formation. The technical conditions of the rust layer stability of weathering steel can be classified into four grades (from 1 to 4) based on three evaluation indicators: the stability of the rust layer on the load-bearing structure, the technical conditions of ancillary bridge structures, and the environmental conditions to which the bridge is exposed. Based on a comprehensive evaluation, the technical condition of rust layer stability of Changxing No. 2 Bridge in Meixian County, Longfang Overpass Bridge of Huangyan Expressway, and Daguo Bridge of Zhamo Highway in Xizang was rated as Grade 2, Grade 2, and Grade 3, respectively. Stable and reliable rust layers on weathering steel are a technical guarantee for designing and utilizing long-lasting weathering steel bridges. The inspection method and evaluation index for rust layer stability of long-lasting weathering steel bridges can provide support for bridge structural design and rust layer maintenance, promoting the engineering application of long-lasting weathering steel bridges.
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图 4 免涂装耐候钢桥锈层稳定性技术状况评定
Figure 4. Technical condition assessment of rust layers stability for uncoated weathering steel bridges
图 8 眉县常兴二号桥锈层目测检查
Figure 8. Visual inspection of rust layer on Changxing No.2 Bridge in Meixian County
图 9 黄延高速隆坊跨线桥目测检查
Figure 9. Visual inspection of rust layer on Longfang Overpass Bridge of Huangyan Expressway
图 11 耐候钢桥锈层检查、维护策略流程
Figure 11. Inspection and maintenance strategy process for rust layer on weathering steel bridges
表 1 锈层检测方法对比
Table 1. Comparison of rust layer detection methods
检测方法 优点 缺点 目测检查法 直观简便 评价对经验依赖性大 胶带黏附力测试法 操作方便，样本可长期保存 隐蔽区域检测困难 超声波测厚法 实现无损检测 精密仪器现场操作不便 XRD成分分析法 锈蚀成分测 氯化物测试法 对氯离子含量敏感 操作步骤繁琐 
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表 2 耐候钢桥锈层稳定性等级评价模型
Table 2. Evaluation model of rust layer stability of weathering steel bridge
锈层等级 锈层外观 外观特征 胶带黏附力测试样本 分类指标 等级1 
颜色：巧克力或深棕色、颜色均匀
纹理：致密且连续、表面平整
网格线图案纹理
ρs < 2%等级2 
颜色：深棕色或带有黑色锈斑
纹理：较致密、表面较平整
Rs＜1 mm
2%≤ρs＜6%等级3 
颜色：浅褐到黑色变化大
纹理：表面不平整、存在分层脱落、均匀性差
1 mm≤Rs＜2 mm
2%≤ρs＜15%等级4 
颜色：亮黄到黑色，局部颜色突变，差异明显
纹理：表面粗糙、不均匀，锈斑、锈坑明显
1 mm≤Rs＜2 mm ρs≥15%
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表 3 耐候钢锈层量化分级标准对比
Table 3. Comparison of quantitative classification standards for weathering steel rust layer
锈层等级 美国爱荷华州交通厅 日本钢铁联合会和日本钢桥建设协会 中国《色漆和清漆 划格试验》(GB/T 9286—2021) 等级1 等级7、8 等级4、5 等级0、1 等级2 等级6 等级3 等级2 等级3 等级5 等级2 等级3 等级4 等级3、4 等级1 等级4、5
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表 4 不同类型耐候钢桥锈层稳定性评价对象权重
Table 4. Weighting factors for rust layer stability in different types of weathering steel bridges
评定指标 评价对象 权重 总权重 钢板(管翼缘)梁锈层状况 下翼板 0.69 0.60 腹板 0.23 上翼板 0.08 钢桁梁锈层状况 主桁腹杆 0.36 主桁弦杆 0.52 横联与平联 0.12 附属结构 防排水系统 0.25 伸缩装置 桥位环境 湿度、氯离子、二氧化硫含量 0.15
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表 5 锈层稳定性等级扣分值
Table 5. Stability grades and deduction points of rust layer
稳定性等级 锈层状态描述 扣分值 1 锈层状态完好，形成稳定耐候锈层 0 2 锈层有轻微破损，表面锈层有轻度脱落 20 3 锈层产生中等破损，会影响侵蚀病害进一步加剧 40 4 锈层存在严重破损，锈液流挂 60
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表 6 桥梁附属结构技术状况评价
Table 6. Technical condition assessment of bridge subsidiary structure
失效评价指标 防排水系统 伸缩装置 得分 情形1 √ √ 100 情形2 √ × 90 情形3 × √ 40 情形4 × × 0
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表 7 桥位环境状况评价
Table 7. Bridge environmental condition evaluation
腐蚀大气环境类型 C1 C2 C3 C4 C5 CX 气候区域特征 干冷地区(污染非常低) 温带或干冷地区 温带地区或亚热带和热带地区(低污染大气) 温带地区，受氯化物重大影响 温带和亚热带地区，受氯化物重大影响 亚热带和热带地区，受氯化物强烈影响 SO2浓度/(μg·m-3) ≤5 (5, 30] (30, 90] (90, 250] ＞250 状况评分 100 80 60 40 20 0
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表 8 免涂装耐候钢桥锈层稳定性技术状况评级
Table 8. Technical condition grading for rust layer stability on uncoated weathering steel bridges
锈层技术状况 1级 2级 3级 4级 D [80, 100] [60, 80) [40, 60) [0, 40)
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表 9 锈层测试位置
Table 9. Rust layer test locations
编号 检测对象 检查时间 测试位置 1 眉县常兴二号桥 2022年4月 主梁腹板、下翼板、管翼缘，主梁焊缝附近 2 黄延高速隆坊跨线桥 2021年10月 主梁腹板、下翼板、管翼缘 3 西藏扎墨公路达国大桥 2021年7月 主桁弦杆、腹杆，横联、平联
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表 10 眉县常兴二号桥锈层稳定性测试结果
Table 10. Test results of rust layer stability on Changxing No.2 Bridge in Meixian County
锈层等级 锈层外观 外观特征 胶带黏附力测试样本 分类指标 分布位置 等级1 
颜色：巧克力色
纹理：表面平整、均匀且致密
网格线图案纹理
ρs < 2%①中主梁腹板；
②端横梁腹板中部；
③中主梁下翼板上表面等级2 
颜色：带深色点状锈蚀群
纹理：存在竖向纹理，较致密，不均匀
Rs＜1 mm
2%≤ρs < 6%①边主梁腹板外侧中下部；
②边主梁管翼缘外侧；
③腹板中部焊缝附近等级3 
颜色：浅褐到黑色变化大
纹理：表面不平整，存在分层脱落，均匀性差
1 mm≤Rs＜2 mm
2%≤ρs < 15%①边主梁腹板外侧与下翼板相接处；
②边主梁下翼板上表面等级4 
颜色：亮黄到黑色，局部颜色突变，差异明显
纹理：表面粗糙、不均匀
1 mm≤Rs＜2 mm ρs≥15% 边主梁下翼板外侧底面局部异常腐蚀位置
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表 11 黄延高速隆坊跨线桥锈层稳定性测试结果
Table 11. Test results of rust layer stability on Longfang Overpass Bridge of Huangyan Expressway
锈层等级 锈层外观 外观特征 胶带黏附力测试样本 分类指标 分布位置 等级1 
颜色：亮棕色
纹理：表面平整、均匀且致密
网格线图案纹理
ρs < 2%①中主梁腹板中部；
②中主梁下翼板下表面等级2 
颜色：呈浅棕色
纹理：存在竖向纹理、较致密、不均匀
Rs＜1 mm
2%≤ρs < 6%边主梁腹板中下位置 等级3 
颜色：浅褐到黑色变化大
纹理：表面不平整、存在分层脱落、均匀性差
1 mm≤Rs＜2 mm
2%≤ρs < 15%①边主梁腹板外侧靠近下翼板附近；②边主梁管翼缘外侧 等级4 
颜色：亮黄到黑色，局部颜色突变明显
纹理：表面粗糙
1 mm≤Rs＜2 mm ρs≥15% 边主梁下翼板上表面局部
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表 12 达国大桥锈层稳定性测试结果
Table 12. Test results of rust layer stability on Daguo Bridge
锈层等级 锈层外观 外观特征 胶带黏附力测试样本 分类指标 分布位置 等级1 
颜色：亮褐色，少量棕色斑点
纹理：表面平整、均匀且致密
网格线图案纹理
ρs < 2%①上游主桁竖腹杆；
②上游主桁斜腹杆等级2 
颜色：呈浅褐色
纹理：存在少量蚀坑、较致密、不均匀
Rs＜1 mm
2%≤ρs＜6%①下平联弦杆顶板上表面；
②横联斜腹杆等级3 
颜色：浅褐到深褐色变化大
纹理：表面不平整、存在分层脱落、均匀性差
1 mm≤Rs＜2 mm
2%≤ρs＜15%①下游主桁竖腹杆；
②下游主桁斜腹杆等级4 
颜色：棕色到黑色，局部颜色突变，差异明显
纹理：表面粗糙、不均匀
1 mm≤Rs＜2 mm ρs≥15% 下游侧钢桥面板U肋侧面
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表 13 免涂装耐候钢桥锈层稳定性技术状况计算实例
Table 13. Case study on technical condition calculation of rust layer stability for uncoated weathering steel bridge
评价指标 眉县常兴二号桥(管翼缘组合梁桥) 黄延高速隆坊跨线桥(管翼缘组合梁桥) 西藏扎墨公路达国大桥(上承式钢桁梁悬索桥) 评价对象 评分值 评价对象 评分值 评价对象 评分值 锈层状况 下翼板 23.2 下翼板 22.2 主桁腹杆 13.0 腹板 11.6 腹板 10.5 主桁弦杆 16.1 管翼缘 4.8 管翼缘 4.8 横联与平联 5.8 附属结构 防排水系统、伸缩装置均正常 25.0 防排水系统、伸缩装置均正常 25.0 防排水系统、伸缩装置均正常 25.0 桥位环境 腐蚀环境分类为C2 12.0 腐蚀环境分类为C2 12.0 腐蚀环境分类为C3 9.0 评价总分 76.6 74.5 68.9
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表 14 耐候钢桥日常维护方法
Table 14. Routine maintenance methods for weathering steel bridges
维护项目 现象 维护方法 主梁表面锈层维护 表面灰尘杂物堆积，除冰盐残留 周期性低压水清洗，避免破坏锈层 连接构造细节检查 焊缝、螺栓连接处锈蚀 定期检查，采取局部涂装或维护更换 防排水系统检查 伸缩缝破损，排水管道漏水 检查漏水源头，维修更换失效构件 周围环境检查 桥台处灌木植被遮蔽 清理桥台周围遮挡植被露出梁端主体结构
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