Ulf NürnbergerN. Contribution of the group Metallic

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1 COST 534 FINAL WORKSHOP, November 2007, TOULOUSE, FRANCE Ulf NürnbergerN Prestressing steel- Corrosion damages and application of stainless steel tendons Contribution of the group Metallic Tendons U. Nürnberger, Y. Wu, University of Stuttgart, Germany M. C. Alonso, F. J. Recio, Instituto Eduardo Torroja, Madrid, Spain University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 1

2 fracture of the prestressing cables in the moment tension zone Collapse of a prestressed concrete beam of a laboratory roof after 35 years in use University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 2

3 insufficient design (poor construction) incorrect execution of planned design (poor workmanship) unsuitable mineral building materials unsuitable post-tensioning system components including the prestressing steel Reasons of damages of prestressing steel University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 3

4 Preconditions for H-SCC: H - sensitive material or state, - sufficient high tension load, - at least a slight corrosion attack. Hydrogen induced cracks and fractures of cold deformed wire wrapped around a concrete tube University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 4

5 electrolyte plastic zone A B C metal D A Electrochemical corrosion processes on the steel surface with cathodic hydrogen evolution: anodic reaction : Fe Fe e - (iron dissolution) cathodic reaction: 2H + + 2e - 2H (discharging hydrogen) B absorption and diffusion of atomic hydrogen C hydrogen assisted crack formation D crack propagation Mechanism of hydrogen assisted stress corrosion cracking University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 5

6 corrosion product (rust) corrosion pit crack in corrosion pit: hydrolysis FeCl 2 + 2H 2 O Fe(OH) 2 + 2HCl crack pre-cracks crack Mechanism of pitting induced stress corrosion cracking of high strength steel University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 6

7 surface (scanning microskope) 1cm = 30 µm 1cm = 30 µm metallographical slip crack corrosion pit pitting precrack mill scale Pitting induced stress corrosion cracking (H-SCC) University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 7

8 - Advantages of stainless steels in comparison to other corrosion protection methods in hevealy chloride contaminated concrte. - Successful application of high strength stainless steel strands for ropes and cables for bridges, roofs etc.. - Successful introduction of stainless of steel reinforcement in carbonated and chloride containing reinforced concrete because of very high corrosion resistivity. Reasons for application of prestressing stainless steel University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 8

9 The question is: Can we transfer the positive experiences from high strength stainless steel cables and stainless steel reinforcement to prestressed concrete? University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 9

10 Application of stainless steel spiral ropes as hangers on a foot-bridge in Stuttgart University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 10

11 tensile strength R m in N/mm 2 min. R m Austenitic chromium-nickel steels have a pronounced tendency towards work hardening. Therefore the strength of wires can be increased by cold-deformation. To reach a notified strength of 1450 N/mm 2 the wires must be deformed till a degree of 50 to 70%. Not too high alloyed stainless steels with a structure instability tend to formation of martensite. Martensite in the austenitic structure increases the strength. However, it may lead to a worse corrosion behaviour cold-deformation in % Production of high strength stainless steel strands University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 11

12 (X5CrNi 18-10) no application for ropes in Germany (X5CrNiMo ) application for ropes in not contaminated urban atmosphere (X3CrNiMo ) application for ropes in chloride contaminated atmosphere (de-icing salt spray) (X2CrNiMoN ) application for ropes in offshore structures Investigated materials for prestressed concrete and their present application for ropes outside concrete University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 12

13 CrNi r = CrNiMo r = 1.2 austenite-stability increases with the alloy elements as follows: AS 14Cr + 10Ni + 19Mo CrNiMo r = : µ r = 17.7 much martensite : µ r = 1.2 very low martensite : µ r = 1.0 no martensite Test results of the magnetic permeability r of stainless prestressing steel (permeability = ferromagnetic behaviour, corresponds to the austenite stability and with the martensite portion in the austenitic structure after cold deformation) University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 13

14 high strength and sufficiently high proof stress sufficiently high ductility sufficiently relaxation behaviour under performance load good behaviour in (wedge) anchorage systems sufficiently high dynamic loadability high corrosion resistance against - pitting corrosion - anodic SCC - hydrogen assisted SCC under atmospheric corrosion conditions (transport, handling on site etc.) and in carbonated and/or chloride containing concrete Necessary performance characteristics of prestressing steel for application in concrete University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 14

15 The pitting corrosion potentials of cold drawn high strength stainless steel wires were determined by potentiostatic current-potential measurements with mortar electrodes in - alkaline concrete - carbonated concrete with 5% chloride relative to cement weight. The results have been compared with those of cold drawn low strength reinforcing steels (deformation degree 36 %) of the same composition and similar surface condition. Potentiostatic determination of the pitting corrosion potential on high strength stainless steel wires with mortar electrodes University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 15

16 pitting corr. potential E p in mv-cal 600 alkaline carbonated reinforcing steel prestressing steel E P decreases in the order In carbonated concrete the E P is significantly lower than in alkaline concrete. The difference between E P - reinforcing steel and E P - prestressing steel increases in the order (reason: martensite). It is expected that E P of prestressing steel in carbonated concrete CrNiMo CrNiMo CrNi CrNiMo CrNiMo CrNi (tests not finished) will be unacceptable low. After these tests the prestressing steel can be recommended for highly chloride-contaminated concrete: The higher deformation grade does not very badly affect the pitting corrosion behaviour. Pitting corrosion potential of cold-drawn stainless steels in alkaline and carbonated concrete with 5 mass-% Cl University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 16

17 pitting corr. potential E p in mv-cal ph 13, (X5CrNi 18-10) (X3CrNiMo ) (X5CrNiMo ) ph 8,5 0 0,2 0,4 0,6 0,8 1,0 chloride concentration in Mol Pitting corrosion potential for high strength stainless steel in solutions representing alkaline and carbonated concrete polluted with chlorides University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 17

18 The threshold temperatures of stressed single wires in saturated chloride solutions were determined by isotherm exposure tests on bending specimens. The threshold temperature is that temperature, below that no SCC can occur (X5CrNi 18-10) material (X5CrNiMo ) (X3CrNiMo ) (X2CrNiMoN ) solution 1: calciumhydroxide solution, ph= saturated NaCl-solution solution condition solution 2: carbonate/bicarbonate, ph=8.5 buffer solution + saturated NaCl-solution solution 3: acetic acid/sodium-acetate, ph=4.5 buffer solution + saturated NaCl-solution temperature test time 30 C 40 C 50 C 60 C 80 C > h Anodic stress corrosion tests in saturated chloride solutions University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 18

19 new broken 100 µm bending specimen Specimens for anodic SCC-test broken specimen: ph = 8.5 temperature = 80 C steel = lifetime = 765h University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 19

20 ph life time in h ph 4.5 ph ph temperature in C The resistance to anodic Cl- SCC rises with increasing ph-value decreasing temperature of media increasing steel quality ( ) After these tests the prestressing steel can be recommended for highly chloridecontaminated concrete. Results of SCC - tests of cold-drawn high-strength stainless steel wires in chloride-saturated solutions of different temperature and ph-value University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 20

21 testing frame tempered test vessel SCC-tests on centrically stressed wires in aqueous solutions under hydrogen charge stressed wire University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 21

22 test conditions materials CrNi CrNiMo CrNiMo FIP - test: R = 80% R m, 50 C, 20% NH 4 SCN-solution 145 h 2830 h no fracture within 4000 h FIP - test with cathodic polarisation to -1000mV 102 h 860 h no fracture within 4000 h FIP - test with pre-corrosion by MgCl 2 spots 91 h 250 h no fracture within 4000 h the lifetime decreases in the order , It seems that martensite reduces considerably the hydrogen resistance, the lifetime of exceed those of conventional prestressing steels. Hydrogen - induced SCC behaviour of prestressing stainless steel wires (mean value of life times in h from 3 tests) University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 22

23 All tests carried through have shown that high strength stainless steel wires of quality are resistant enough to withstand pitting and stress corrosion cracking in strongly chloride contaminated concrete. In case of deformation martensite increases in a not acceptable degree the suceptibility to all kinds of corrosion. Our results correspond with the results from the investigations of Instituto Eduardo Torroja in Madrid Conclusion University of Stuttgart, Germany, and Instituto Eduardo Torroja, Madrid, Spain 23

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