Assessment of Weathering Steel Bridge Performance in Iowa and Development of Inspection and Maintenance Techniques, RB17-012, 2013

Weathering steel is commonly used as a cost-effective alternative for bridge superstructures, as the costs and environmental impacts associated with the maintenance/replacement of paint coatings are theoretically eliminated. The performance of weathering steel depends on the proper formation of a surface patina, which consists of a dense layer of corrosion product used to protect the steel from further atmospheric corrosion. The development of the weathering steel patina may be hindered by environmental factors such as humid environments, wetting/drying cycles, sheltering, exposure to de-icing chlorides, and design details that permit water to pond on steel surfaces. Weathering steel bridges constructed over or adjacent to other roadways could be subjected to sufficient salt spray that would impede the development of an adequate patina. Addressing areas of corrosion on a weathering steel bridge superstructure where a protective patina has not formed is often costly and negates the anticipated cost savings for this type of steel superstructure. Early detection of weathering steel corrosion is important to extending the service life of the bridge structure; however, written inspection procedures are not available for inspectors to evaluate the performance or quality of the patina. This project focused on the evaluation of weathering steel bridge structures, including possible methods to assess the quality of the weathering steel patina and to properly maintain the quality of the patina. The objectives of this project are summarized as follows:  Identify weathering steel bridge structures that would be most vulnerable to chloride contamination, based on location, exposure, environment, and other factors.  Identify locations on an individual weathering steel bridge structure that would be most susceptible to chloride contamination, such as below joints, splash/spray zones, and areas of ponding water or debris.  Identify possible testing methods and/or inspection techniques for inspectors to evaluate the quality of the weathering steel patina at locations discussed above.  Identify possible methods to measure and evaluate the level of chloride contamination at the locations discussed above.  Evaluate the effectiveness of water washing on removing chlorides from the weathering steel patina.  Develop a general prioritization for the washing of bridge structures based on the structure’s location, environment, inspection observations, patina evaluation findings, and chloride test results.

Harustetun 110 kV kannatuspylvään konseptin kehittäminen

Diplomityössä kehitettiin harustetun 110 kV kannatuspylvään konsepti tuotteeksi. Pylväs on säänkestävästä teräksestä valmistettu putkipalkkirakenteinen I-pylväs. Tavoitteena oli suunnitella rakenteesta kokonaistaloudellisesti edullinen. Rakenteen suunnittelussa otettiin huomioon valmistus-, kuljetus- ja varastointi- sekä rakentamisnäkökohtia. Työssä perehdyttiin pylväsrakenteiden yksityiskohtiin, putkipalkkien liitosmenetelmiin ja pylvään jalan nivelöintiratkaisuihin. Säänkestävä rakennemateriaali otettiin huomioon rakennesuunnittelussa. Rakenteen lujuusteknisen suunnittelun apuna käytettiin epälineaarista elementtimenetelmää. Pylväsrakenteen käyttäytyminen mallinnettiin geometrisesti epälineaariseksi, ja liitosdetaljien analysointia varten kehitettiin epälineaarisia materiaalimalleja. Rakenteen värähtelykäyttäytyminen analysoitiin myös elementtimenetelmällä. Lopputuloksena saatiin aikaan pylväs, joka täyttää sille asetetut vaatimukset. Pylväs on helposti valmistettava, kuljetettava ja pystytettävä.

Corrosione atmosferica in area urbana-costiera di un acciaio Cor-Ten: studio del rilascio in ambiente dei metalli di lega

Cor-Ten is a particular kind of steel, belonging to low-alloyed steel; thanks to his aesthetic features and resistance to atmospheric corrosion, this material is largely used in architectural, artistic and infrastructural applications. After environmental exposure, Cor-Ten steel exhibits the characteristic ability to self-protect from corrosion, by the development of a stable and adherent protective layer. However, some environmental factors can influence the formation and stability of the patina. In particular, exposure of Cor-Ten to polluted atmosphere (NOx, SOx, O3) or coastal areas (marine spray) may cause problems to the protective layer and, as a consequence, a release of alloying metals, which can accumulate near the structures. Some of these metals, such as Cr and Ni, could be very dangerous for soils and water because of their large toxicity. The aim of this work was to study the corrosion behavior of Cor-Ten exposed to an urban-coastal site (Rimini, Italy). Three different kinds of commercial surface finish (bare and pre-patinated, with or without a beeswax covering) were examined, both in sheltered and unsheltered exposure conditions. Wet deposition brushing the specimens surface (leaching solutions) are monthly collected and analyzed to evaluate the extent of metal release and the form in which they leave the surface, for example, as water-soluble compounds or non-adherent corrosion products. Five alloying metals (Fe, Cu, Cr, Mn and Ni) and nine ions (Cl-, NO3-, NO2-, SO42-, Na+, Ca2+, K+, Mg2+, NH4+) are determined through Atomic Absorption Spectroscopy and Ion Chromatography, respectively. Furthermore, the evolution and the behaviour of the patina are periodically followed by surface investigations (SEM-EDS and Raman Spectroscopy). After two years of exposure, the results show that Bare Cor-Ten, cheaper than the other analyzed specimens, even though undergoes the greater mass variation, his metal release is comparable to the release of the pre-patinated samples. The behavior of pre-patinated steel, with or without beeswax covering, do not show particular difference. This exposure environment doesn’t allow a completely stabilization of the patina; nevertheless an estimate of metal release after 10 years of exposure points out that the environmental impact of Cor-Ten is very low: for example, the release of chromium in the soluble fraction is less than 10 mg if we consider an exposed wall of 10 m2.

Evaluation of a Bridge Constructed using High Performance Steel, May 2006

Of the approximately 25,000 bridges in Iowa, 28% are classified as structurally deficient, functionally obsolete, or both. Because many Iowa bridges require repair or replacement with a relatively limited funding base, there is a need to develop new bridge materials that may lead to longer life spans and reduced life-cycle costs. In addition, new and effective methods for determining the condition of structures are needed to identify when the useful life has expired or other maintenance is needed. Due to its unique alloy blend, high-performance steel (HPS) has been shown to have improved weldability, weathering capabilities, and fracture toughness than conventional structural steels. Since the development of HPS in the mid-1990s, numerous bridges using HPS girders have been constructed, and many have been economically built. The East 12th Street Bridge, which replaced a deteriorated box girder bridge, is Iowa’s first bridge constructed using HPS girders. The new structure is a two-span bridge that crosses I-235 in Des Moines, Iowa, providing one lane of traffic in each direction. A remote, continuous, fiber-optic based structural health monitoring (SHM) system for the bridge was developed using off-the-shelf technologies. In the system, sensors strategically located on the bridge collect raw strain data and then transfer the data via wireless communication to a gateway system at a nearby secure facility. The data are integrated and converted to text files before being uploaded automatically to a website that provides live strain data and a live video stream. A data storage/processing system at the Bridge Engineering Center in Ames, Iowa, permanently stores and processes the data files. Several processes are performed to check the overall system’s operation, eliminate temperature effects from the complete strain record, compute the global behavior of the bridge, and count strain cycles at the various sensor locations.

Remote Continuous Evaluation of a Bridge Constructed Using High-Performance Steel, 2006

Of the approximately 25,000 bridges in Iowa, 28% are classified as structurally deficient, functionally obsolete, or both. The state of Iowa thus follows the national trend of an aging infrastructure in dire need of repair or replacement with a relatively limited funding base. Therefore, there is a need to develop new materials with properties that may lead to longer life spans and reduced life-cycle costs. In addition, new methods for determining the condition of structures are needed to monitor the structures effectively and identify when the useful life of the structure has expired or other maintenance is needed. High-performance steel (HPS) has emerged as a material with enhanced weldability, weathering capabilities, and fracture toughness compared to conventional structural steels. In 2004, the Iowa Department of Transportation opened Iowa's first HPS girder bridge, the East 12th Street Bridge over I-235 in Des Moines, Iowa. The objective of this project was to evaluate HPS as a viable option for use in Iowa bridges with a continuous structural health monitoring (SHM) system. The scope of the project included documenting the construction of the East 12th Street Bridge and concurrently developing a remote, continuous SHM system using fiber-optic sensing technology to evaluate the structural performance of the bridge. The SHM system included bridge evaluation parameters, similar to design parameters used by bridge engineers, for evaluating the structure. Through the successful completion of this project, a baseline of bridge performance was established that can be used for continued long-term monitoring of the structure. In general, the structural performance of the HPS bridge exceeded the design parameters and is performing well. Although some problems were encountered with the SHM system, the system functions well and recommendations for improving the system have been made.

Mitigation of High Alkalinity in Leachates of Aged Steel Slag

Steel slag, an abundant by-product of the steel-making industry, after it is aged, has a huge potential for use as an aggregate in road construction. However, the high pH of steel slag seepage (pH≥12) is a major impediment in its beneficial use. Analyses on aged steel slag samples demonstrated that the alkalinity producing capacity of aged steel slag samples strongly correlated to Ca(OH)2 dissolution and that prolonged aging periods have marginal effects on overall alkalinity. Treatment methods that included bitumen-coating, bathing in Al(III) solutions and addition of an alum-based drinking water treatment residual (WTR) were evaluated based on reduction in pH levels and leachate alkalinity. 10% (wt./wt.) alum-based drinking water treatment residual (WTR) addition to slag was determined to be the most successful mitigation method, providing 65−70% reduction in alkalinity both in batch-type and column leach tests, but final leachate pH was only 0.5−1 units lower and leachates were contaminated by dissolved Al(+III) (≥3−4 mM). Based on the interpretation of calculated saturation indices and SEM and EDX analyses, formation of calcium sulfoaluminate phases (i.e., ettringite and monosulfate) was suggested as the mechanism behind alkalinity mitigation upon WTR-modification. The residual alkalinity in WTR-amended slag leachates was able to be completely eliminated utilizing a biosolids compost with high base neutralization capacity. In column leach tests, effluent pH levels below 7 were maintained for 58−74 pore volumes worth of WTR-amended slag leachate using 0.13 kg compost (dry wt.) per 1 kg WTR-amended slag on average; also, dissolved Al(+III) was strongly retained on the compost.

Risk optimization of a steel frame communications tower subject to tornado winds

The structural engineering community in Brazil faces new challenges with the recent occurrence of high intensity tornados. Satellite surveillance data shows that the area covering the south-east of Brazil, Uruguay and some of Argentina is one of the world most tornado-prone areas, second only to the infamous tornado alley in central United States. The design of structures subject to tornado winds is a typical example of decision making in the presence of uncertainty. Structural design involves finding a good balance between the competing goals of safety and economy. This paper presents a methodology to find the optimum balance between these goals in the presence of uncertainty. In this paper, reliability-based risk optimization is used to find the optimal safety coefficient that minimizes the total expected cost of a steel frame communications tower, subject to extreme storm and tornado wind loads. The technique is not new, but it is applied to a practical problem of increasing interest to Brazilian structural engineers. The problem is formulated in the partial safety factor format used in current design codes, with all additional partial factor introduced to serve as optimization variable. The expected cost of failure (or risk) is defined as the product of a. limit state exceedance probability by a limit state exceedance cost. These costs include costs of repairing, rebuilding, and paying compensation for injury and loss of life. The total expected failure cost is the sum of individual expected costs over all failure modes. The steel frame communications, tower subject of this study has become very common in Brazil due to increasing mobile phone coverage. The study shows that optimum reliability is strongly dependent on the cost (or consequences) of failure. Since failure consequences depend oil actual tower location, it turn,,; out that different optimum designs should be used in different locations. Failure consequences are also different for the different parties involved in the design, construction and operation of the tower. Hence, it is important that risk is well understood by the parties involved, so that proper contracts call be made. The investigation shows that when non-structural terms dominate design costs (e.g, in residential or office buildings) it is not too costly to over-design; this observation is in agreement with the observed practice for non-optimized structural systems. In this situation, is much easier to loose money by under-design. When by under-design. When structural material cost is a significant part of design cost (e.g. concrete dam or bridge), one is likely to lose significantmoney by over-design. In this situation, a cost-risk-benefit optimization analysis is highly recommended. Finally, the study also shows that under time-varying loads like tornados, the optimum reliability is strongly dependent on the selected design life.

Modeling of the Barkhausen jump in low carbon steel

This work presents a model for the magnetic Barkhausen jump in low carbon content steels. The outcomes of the model evidence that the Barkhausen jump height depends on the coercive field of the pinning site and on the mean free path of the domain wall between pinning sites. These results are used to deduce the influence of the microstructural features and of the magnetizing parameters on the amplitude and duration of the Barkhausen jumps. In particular, a theoretical expression, establishing the dependence of the Barkbausen jump height on the carbon content and grain size, is obtained. The model also reveals the dependence of the Barkhausen jump on the applied frequency and amplitude. Theoretical and experimental results are presented and compared, being in good agreement. (C) 2008 American Institute of Physics.

Evolution of magnetic properties and crystallographic texture in electrical steel with large plastic deformation

Deformation leads to a hardening of steel due to an increase in the density of dislocations and a reduction in their mobility, giving rise to a state of elevated residual stresses in the crystal lattice. In the microstructure, one observes an increase in the contribution of crystalline orientations which are unfavorable to the magnetization, as seen, for example, by a decrease in B(50), the magnetic flux density at a field of 50 A/cm. The present study was carried out with longitudinal strips of fully processed non-oriented (NO) electrical steel, with deformations up to 70% resulting from cold rolling in the longitudinal direction. With increasing plastic deformation, the value of B(50) gradually decreases until it reaches a minimum value, where it remains even for larger deformations. On the other hand, the coercive field H(c) continually increases. Magnetometry results and electron backscatter diffraction results are compared and discussed. (C) 2011 American Institute of Physics. [doi: 10.1063/1.3560895]

Deep weathering and landscape evolution in a tropical plateau

The thick weathering profiles of humid tropical areas are an important, yet generally neglected, source of information on landscape evolution. Six complete profiles of the weathering mantle were sampled by drilling on the three stepped levels of the Campos do Jordao Plateau, on the NW flank of the Continental Rift of Southeastern Brazil. Mineralogical and micromorphological analyses of drill core samples, complemented by geochemical interpretations and by previous data on the upper saprolite, indicate continuity of a general lateritic trend during the entire process of mantle formation. Lateritization phases of different intensity were defined and considered to reflect adjustment to changes in environmental conditions created by the gradual uplift of the plateau to its present position. Older and more superficial materials related to intense lateritic weathering are characterized by allitization with direct formation of gibbsite from silicates, probably related to tropical climates existing immediately before the formation of the continental rift, during the Paleogene, and also before any significant increase in altitude. Monosialitization phase with general kaolinitization and restricted indirect formation of gibbsite from silicates could be associated to less aggressive climates that followed the Neogene (Miocene?) accentuation of uplift rates along the continental rift. The changes produced by uplift in the tropical climate eventually favored the development of a podzolization trend in soils above 1800m. (C) 2011 Elsevier BM. All rights reserved.

Assessing land availability to produce biomass for energy: The case of Brazilian charcoal for steel making

The paper discusses the availability of biomass in Brazil to supply charcoal to the steel industry on the bases of an initial global assessment of land potentially available for plantations and of Brazilian data that allows refining the assessment and specifying the issue of practical availability. Technical potentials are first assessed through a series of simple rules against direct competition with agriculture, forests and protected areas, and of quantitative criteria, whether geo-climatic (rainfall), demographic (population density) or legal (reserves). Institutional, social and economic factors are then identified and discussed so as to account for the practical availability of Brazilian biomass through six criteria. The ranking of nine Brazilian States according to these criteria brings out the necessary trade-offs in the selection of land for plantations that would efficiently supply charcoal to the steel industry. (C) 2008 Elsevier Ltd. All rights reserved.

Morphological analysis of pitting corrosion in AISI 310S austenitic stainless steel after salt spray exposition

This paper aims to study evolution of increase, distribution and classification of pits in 310S austenitic stainless steels obtained in the state as-received and heat-treated under different exposure times in saline. This work applicability has been based on a technique development for morphologic characterization of localized corrosion associated with description aspects of shapes, size and population-specific parameters. Methodology has been consisted in the following steps: specimens preparation, corrosion tests via salt spray in different conditions, microstructural analysis, pits profiles analysis and images analysis, digital processing and image analysis in order to characterize the pits distribution, morphology and size. Results obtained in digital processing and profiles image analysis have been subjected to statistical analysis using median as parameter in the alloy as received and treated. The alloy as received displays the following morphology: hemispheric pits> transition region A> transition region B> irregular> conic. The pits amount in the treated alloy at each exposure time is: transition region B> hemispherical> transition region A> conic> irregular.

Woodgrain defect on tinned steel Flandres foil

Tin electrocoated steel strip, also referred to as Flandres foil, is largely used for manufacturing food containers. Tinplates must have good corrosion resistance, workability, weldability, as well as a bright appearance. The woodgrain defect, a not yet fully understood defect that occurs on tinplates and accounts for their high scrap rate, consists of alternate bands of bright/dull reflectivity and resembles longitudinally cut wood. Observations of the woodgrain defect by scanning electron microscopy showed that the molten tin spreads irregularly during both the melting and solidification stages. X-ray diffraction analyses showed that the metallic tin tended to crystallize in the (200) direction for coupons with and without the woodgrain defect. Nevertheless, the preferential orientation degree decreased for coupons with the woodgrain defect. The rocking curves, also known as omega-scan, showed that the tin grains were uniformly aligned parallel to the strip surface for coupons with no defects, whereas for tinplates with woodgrain, the tin grains were not uniformly oriented, probably due to the misalignment of the grains in relation to the surface. (C) 2011 Elsevier Inc. All rights reserved.

Annealing effects on microstructure and coercive field of ferritic-martensitic ODS Eurofer steel

Oxide dispersion strengthened reduced-activation ferritic-martensitic steels are promising candidates for applications in future fusion power plants. Samples of a reduced activation ferritic-martensitic 9 wt.%Cr-oxide dispersion strengthened Eurofer steel were cold rolled to 80% reduction in thickness and annealed in vacuum for 1 h from 200 to 1350 degrees C to evaluate its thermal stability. Vickers microhardness testing and electron backscatter diffraction (EBSD) were used to characterize the microstructure. The microstructural changes were also followed by magnetic measurements, in particular the corresponding variation of the coercive field (H(c)), as a function of the annealing treatment. Results show that magnetic measurements were sensitive to detect the changes, in particular the martensitic transformation, in samples annealed above 850 degrees C (austenitic regime). (C) 2010 Elsevier B.V. All rights reserved.

Influence of laser surface texturing on surface microstructure and mechanical properties of adhesive joined steel sheets

This work discusses the resultant microstructure of laser surface treated galvanised steel and the mechanical properties of adhesively bonded surfaces therein. The surface microstructure obtained at laser intensities between 170 and 1700 MW cm 22 exhibit zinc melting and cavity formation. The wavy surface morphology of the treated surface exhibits an average roughness Ra between 1.0 and 1.5 mu m, and a mean roughness depth R(z) of 8.6 mu m. Atomic force microscopic analyses revealed that the R(z) inside the laser shot cavities increased from 68 to 243 nm when the incident laser intensity was increased from 170 to 1700 MW cm(-2). X-ray fluorescence analyses were used to measure Zn coating thicknesses as a function of process parameters. Both X-ray fluorescence and X-ray diffraction analyses demonstrated that the protective coating remains at the material surface, and the steel structure beneath was not affected by the laser treatment. Tensile tests under peel strength conditions demonstrated that the laser treated adhesively joined samples had resistance strength up to 88 MPa, compared to a maximum of only 23 MPa for the untreated surfaces. The maximum deformation for rupture was also greatly increased from 0.07%, for the original surface, to 0.90% for the laser treated surfaces.