Beruflich Dokumente
Kultur Dokumente
Introduction Manufacturing of Steel Properties of Steel Steel Products for Construction Joining of Steel Durability of Steel
CONSTRUCTION MATERIALS
IRON & STEEL
Source: Wikipedia
IRON
Iron is the 10th most abundant element in the universe Iron accounts for about 35% of earths mass, most of it is in the inner core Earth crust contains about 5% of iron, the 2nd most abundant metal (the first being aluminum)
IRON
The relatively low cost of iron and its high strength make it the most-used metal in the world. The majority of iron is in the form of steels, which are alloys of iron with different metals and carbon.
Source: Wikipedia 3
Source: Wikipedia 4
MANUFACTURING OF STEEL
Manufacturing of Steel Iron Ore Pig Iron (Step 1) Cast Iron Pig Iron Steel (Step II) Steel Alloy Forming of Steel (Step III)
5
Iron Ore
Blast Furnace
Pig Iron
Steel
Blooming Mill
Steel Products
MANUFACTURING OF STEEL
Hematite
Source: Momlouk and Zaniewski (2006) 7
Magnetite
Picture Source: Wikipedia 8
Carbon monoxide reacts with iron ore to become carbon dioxide (CO2) 3 CO + Fe2O3 2 Fe + 3 CO2
Limestone (CaCO3) is used as a flux (solvent) to help removing the impurities, such as silicon dioxide in the ore CaO + CO2 CaSiO3 Slag The molten slag is lighter than the molten iron, so it floats on the top and can be drawn off through an opening at the bottom of the furnace this can later be used as cement replacement material in concrete (Recall GGBS = Ground Granulated Blast Furnace Slag)
10
CAST IRON
Cast iron is produced by reheating pig iron and remove some of the impurities. It contains about 2-4% of carbon It can be cast into molds It is brittle and best used in compression rather than tension Common applications are pipes and fittings. Cast iron is difficult to weld.
Source: Marotta (2005) 11
CAST IRON
4 main types
White cast iron: The carbon and iron are in the form of iron carbide (Fe3C). It is hard and very brittle so it is not used as structural components. It may be used where high resistance to abrasion and wear is required. When broken, the fracture surface appears white. Grey Cast Iron: The carbon is present in the form of graphite flakes. This graphite make it softer and machineable, but it is still very brittle. When broken, the fracture surface appears grey. This is the most common type of cast iron.
Source: wikipedia
12
CAST IRON
Ductile Iron or Spheroidal Graphite Iron: By adding some alloying elements and the right casting procedure, the graphite in the grey cast iron may be induced to form into spherulites (small spheres). This reduce the brittleness. Malleable Iron: By applying heat treatment to the white cast iron, the nodules of graphite may be formed. This helps increase the strength and reduce brittleness.
13
14
Steel Ingot
Source: wikipedia 15
Source: wikipedia 16
STEEL ALLOY
STEEL ALLOY
Source: Momlouk and Zaniewski (2006) Source: Momlouk and Zaniewski (2006) 17 18
STEEL
The largest producer in the world is China, followed by Japan and USA
STEEL
Today, most of the steel is from recycled steel. This has some effects on the chemical compositions of the modern steel by having elements that were not previously considered to be a part of normal steel chemistry It is now become more difficult to find a low-strength grade of steel. We tend to get much higher actual strength for the lower-strength grade of steel.
Source: wikipedia
19
20
PROPERTIES OF STEEL
Properties of metals, in general, may be divided into 2 categories Structure Insensitive Properties : these are properties that has to do with the atoms themselves, but not the microstructure. Examples are density, elastic modulus, coefficient of thermal expansion, specific heat.
PROPERTIES OF STEEL
Properties of Steel Tensile Test & Modulus of Elasticity Impact Test Hardness Test
Structure Sensitive Properties : these are properties that depends on the microstructure of the materials, which is greatly affected by heating and cooling histories. Examples are yield strength, fracture strength, ductility (elongation at failure), and fatigue performance.
23
24
PROPERTIES OF STEEL
We can record the load and the displacement between two points to get a stress-strain plot
25 26
Original
Source: ASCE (2001)
If we reload it again, it will follow the unloading path until it reaches the previous maximum load. After that, it follows the same stress-strain curve as if it is loaded continuously (without unloading) to failure.
29 30
As the yield strength of steel increases (higher strength steel), the yield point becomes more difficult to define. We can define the yield point in this case by using Offset Method, or Proof Stress.
Source: ASCE (2001)
In the design of steel structures, we usually rely on the strength up to the yielding. For simplicity, we generally model the stress-strain curve as bilinear. We know that there is some reserved strength in the Strain Hardening range but we just dont use it in the design.
31
33
34
IMPACT
The Charpy V-Notch Impact test (ASTM E23) is used to measure the energy required to fracture a steel specimen. It uses a hammer pendulum to strike a notched specimen After striking, some of the kinetic energy is absorbed by the test specimen so the swinging arm will not go up as high as its starting position. We can measure the height to compute the energy. The lower the energy required to fracture, the more brittle the steel
HARDNESS
Hardness is the measure of the materials resistance to small dent or scratch to the surface. Most common method is the Rockwell hardness test (ASTM E18) This method measures the penetration depth of small metal ball or diamond cone under a standard load. The hardness value can be used to estimate the tensile strength of the material. This is very useful because hardness test is easy to do, inexpensive, and do not require special specimens.
Notch
Source: Wikipedia Source: Wikipedia Source: Wikipedia
35
36
Compression
Tension
37
38
40
REINFORCING STEEL
Reinforcing bars are obtained by hot rolling of steel Two main types:
Round bar the surface of the bar is smooth Deformed bar the surface of the bar has ribs on it
Structural steel
Hot Rolled steel Cold-formed steel Built-up Members (Steel plate)
The ribs on the surface of deformed bar increase the bond to the concrete. Thus, the Deformed bars are generally used as main reinforcement of structural members. Round bars are generally used as reinforcement to prevent concrete cracking under temperature changes and shrinkage.
Source: Wikipedia
. 20-2543, 24-2548
Type Grade Fy (ksc) Minimum 2400 3000 4000 5000 Fu (ksc) Minimum 3900 4900 5700 6300 Ultimate Strain (%) Minimum 21 17 15 13
SR 24 SD 30 SD 40 SD 50
43
44
Diameter (mm) 6 8 10 12 16 20 22 25 28 32 36 40
Prestressing strands are made by twisting 2, 3, 7, or 19 wires together. The most common type is the 7-wire strand. They are made of higher strength steel than those used in regular reinforcing steel bars . 420-2540:
DB 36 DB 40
48
STRUCTURAL STEEL For steel structures, there are 3 main types of steel members
Hot rolled members Cold-formed members Built-up members (from steel plates)
Source: Wikipedia 52
53
54
55
56
Source: Wikipedia
57
58
61
62
JOINING OF STEEL Structural steel pieces may be join by one of these 3 methods:
JOINING OF STEEL
Rivet High-Strength Bolt Welding
63
Connection Details of the Coalbrookdale Iron Bridge (the first cast iron bridge)
64
RIVET
Rivet is the oldest method of joining. It involves heating a small metal pin until it is sufficiently soft. The metal pin is inserted to the hole and a special tool is used to form the heads of the rivet Riveting is rather slow, requires a lot of skilled workers, cannot carry a lot of loads, and difficult to replace The method is now becomes obsolete due to the invention of high-strength bolts in the 1950s
RIVET
Source: Wikipedia
Source: Wikipedia
Source: Wikipedia
65
66
HIGHSTRENGTH BOLT
High-strength bolt replaces rivet as a steel fastener
Construction of Empire State Tower, 1930
HIGHSTRENGTH BOLT
High-strength bolts are usually tightened such that high tensile stress is developed in the bolt. The tensile stress in the bolt causes compressive stress on the steel pieces being joined. The compressive stress causes friction to develop between the joined piece, holding the pieces together. There are two types of connections:
Slip Critical: The friction is high enough that the pieces must not slip past each other under service load, i.e. the loads are transferred through friction only. Bearing Type: The slippage is allowed under service load. The load is transferred by bearing and shearing of bolts.
Source: Salmon and Johnson (1996)
It takes about 4-5 highly skilled workers to install a rivet (not included in the picture are workers heating the rivet)
HIGHSTRENGTH BOLT
WELDING
Welding is the joining of metal by applying heat to fuse the two pieces together The history of metal welding dates back to the Egyptian period (3000 B.C.). The modern welding method was invented around 1885. A lot of improvements to the process occurred during 1930-1950. There are several welding methods but the most popular are Arc Welding and Gas Welding Arc welding uses an arc between the electrode and the grounded base metal to heat both metals to their melting points. The electrode is coated with flux, which provide the oxygen-free atmosphere around the weld to prevent oxidation. The flux cools down to become slag covering the weld area. Gas welding also uses an arc to heat the metal. However, it uses gas from external sources, such as inert gases or CO2, to shield the weld from oxidation. This is often used in small welds because there is no slag formation.
69
70
WELDING
WELDING
Some types of structural steel are better than the others for welding, depending on its chemical composition Electrode must be selected to match the strength of the material being joined Diameter of the electrode must be selected to match the size of the weld and the electrical output of welding machine
71
72
WELDING
Weld metal in arc welding is deposited by electromagnetic field, not gravity. Therefore, welding can be done in any positions. Welded connection are usually smaller and more aesthetically pleasing than bolted or riveted connections.
WELDING
Source: Salmon and Johnston (1996) Source: Salmon and Johnson (1996) 73 74
WELDING
WELDING
Residual stress occurs in the welded section in a similar manner to the hot rolled sections: i.e. the parts that cool first will have residual compression. The parts that cool last will have residual tension.
The current practice is to weld parts of built-up structural members in the shop but using bolts to assemble the member in the field.
Field welding is inconvenient, difficult to inspect, and can be expensive Shop welding is faster and looks better than bolting Field Bolting Welds done in fabrication shop
75 76 Source: ASCE (2001)
WELDING
In addition, the location near the weld was subjected to very high heat and fast cooling rate. A Martensite structure was developed, which was very hard and brittle. This is the area where failure often occurs. This area is called Heat Affected Zone (HAZ) To reduce the residual stresses and HAZ, cooling rate of welding must be carefully controlled, especially in large welds.
DURABILITY OF STEEL
Corrosion Prevention of Corrosion Weathering Steel Stainless Steel
77
78
CORROSION
Corrosion is a destruction of a material by electrochemical reaction. When the steel corrodes, rust is formed. Some rust on the steel reinforcement before placing of concrete is OK Rust on the steel structures must be avoided as it can lead to reduction in strength Steel rust at the rate of about 0.5mm/year In order for rust to occur, we need 4 elements
Anode: The electrode where corrosion occurs Cathode: The other electrode needed to form a corrosion cell Conductor: A metallic pathway for electrons to flow Electrolyte: A liquid that can support the flow of electrons
CORROSION
Reactions: Anode Side Fe2+ Fe + 2(OH) Fe2+ + 2eFe(OH)2 Ferrous Hydroxide (Black Rust) 4Fe(OH)3 Ferric Hydroxide (Red Rust) 4(OH)-
Steel by itself already has 3 elements, it only needs water (electrolyte) to complete the corrosion cell
79
80
CORROSION
The amount of time the steel stays wet affects the rate of corrosion. Environmental contaminants may accelerate corrosion. Examples are SO2 in acid rain, and salts (from sea or deicing salts).
PREVENTION OF CORROSION
Design the structure such that water cannot collect on the surface or joints
81
82
PREVENTION OF CORROSION
Design the structure such that inspection and maintenance can be done easily
PREVENTION OF CORROSION
Applying protective coating to seal off the surface from moisture.
The surface to be painted must be dry and clean Periodic repainting is necessary
PREVENTION OF CORROSION
Cathodic protection: we prevent the corrosion of steel by making it the cathode side of the corrosion cell!
Sacrificial Anode: this is done by connecting more anodic metal with steel. The anode metal will corrode instead of the steel. This anode metal must be replaced occasionally.
PREVENTION OF CORROSION
Aluminum anodes are mounted on steel structure
Source: Wikipedia
Anodic coating : this is similar to the sacrificial anode but, instead of using a piece of metal, the anode metals is coated on the surface of the steel. Galvanizing: uses Zinc to coat the surface of the steel Zinc-Pigmented Paint: Same concept as galvanizing but in the form of paint
85
Source: Wikipedia
Galvanized Surface
86
PREVENTION OF CORROSION
Impressed Current Cathodic Protection (ICCP): Using external power source to make the metal cathodic and consume the anode metal instead. Inert Anodes such as carbon, titanium, lead, or platinum are used. This is typically used for large structures, such as buried pipelines, as placing sacrificial anodes at regular intervals is impossible.
WEATHERING STEEL
Weathering steel or high strength low-alloy (HSLA) steel (also known commercially as COR-TEN steel) is a steel alloy with very low percentage of carbon (<0.15%) and small amounts of chromium, copper, phosphorus, nickel, niobium, nitrogen, vanadium, molybdenum, silicon, or zirconium Weathering steel has the unique characteristic that, under proper conditions (not too wet and not too dry), it corrodes by forming a dense and tightly adherent oxide barrier that seals out the atmosphere and retards further corrosion. This is in contrast to other steels that form a coarse, porous and flaky oxide that allows the atmosphere to continue penetrating the steel. Although more expensive than the regular carbon steel, we save the cost of painting for the entire service life. ASTM A 242, ASTM A 572, and ASTM A 588
87 88
Source: www.daviddarling.info
Source: www.byauto.com.cn
WEATHERING STEEL
It is widely used in bridges and marine structures. It is not rust-proof. If water collects on the surface, it will corrode.
STAINLESS STEEL
Stainless steel, also known as high-alloy steels, contains 16-28% chromium, up to 22% nickel, and some manganese. It has very high resistance to corrosion due to the forming of a thin, transparent coating of chromium oxide over the surface. It is often used as kitchen tools, laboratory equipments, etc For construction, stainless steel are used as cladding, water pipes/fittings, and corrosion-resistant reinforcement for concrete (ASTM A 955M). Over 150 grades are available, some has higher corrosion resistance than the others, some are harder, some has magnetic property, some are easier to weld, etc Variety of finishes are available from unpolished, brushed, to mirror finishes.
90
Source: Wikipedia
Source: Wikipedia
Source: Wikipedia
Core-Ten Sculpture
STAINLESS STEEL
RECAP
Introduction Manufacturing of Steel Iron Ore Pig Iron Steel Microstructure & Heat Treatment Properties of Steel Tensile Stress-Strain Curve Impact & Hardness Test Factors Affecting Strength Steel Products for Construction Reinforcing steel Round Bar Deformed Bar Prestressing Strands
Source: Wikipedia
Structural steel
Hot Rolled steel Cold-formed steel Built-up Members (Steel plate)
Source: Wikipedia
St. Louis Gateway Arch St. Louis, Missouri, USA Stainless steel cladding
Joining of Steel Riveting, Bolting, Welding Durability of Steel Corrosion Preventions of Corrosion Weathering Steel Stainless Steel
91
Source: Wikipedia
92
REFERENCES
American Society of Civil Engineers (2001), Structural Steel Selection Considerations: A Guide for Students, Educators, Designers, and Builders, Ed. R. Bjorhovde et. al., ASCE, Reston, VA, 110 pages. American Society of Testing and Materials, ASTM A370, West Conshohocken, PA. Illston, J. M. and Domone, P. L. J. (2001), Construction Materials: Their Nature and Behaviour, 3rd Edition, Spon Press, London. Mamlouk, M. S., and Zaniewski, J. P. (2006), Materials for Civil and Construction Engineers, 2nd Edition, Prentice-Hall, NJ, 576 pages Marotta, T. W. (2005), Basic Construction Materials, 7th Edition, Prentice-Hall, NJ, 598 pages Naaman, A. E. (2004), Prestressed Concrete Analysis and Design: Fundamentals, Technopress 3000, Ann Arbor, MI. Nowak, A. S. (2004), Bridge Design Course Materials, University of Michigan, Ann Arbor. Salmon, C. G. and Johnson, J. E. (1996), Steel Structures: Design and Behavior, 4th Edition, HarperCollins College Publishers, NY, 1024 pages. Smith, R.C, and Andres, C.K. (1989), Materials of Construction, 4th Edition, McGraw-Hill, 401 pages. Thai Industrial Standard Institute, TISI 20-2543, Bangkok, Thailand Thai Industrial Standard Institute, TISI 24-2548, Bangkok, Thailand Thai Industrial Standard Institute, TISI 420-2540, Bangkok, Thailand Thai Industrial Standard Institute, TISI 1227-2539, Bangkok, Thailand Thai Industrial Standard Institute, TISI 1228-2537, Bangkok, Thailand Thai Industrial Standard Institute, TISI 1499-2541, Bangkok, Thailand http://www.wikipedia.org
93