Temporary Corrosion Protection

for Strand and Influence of

Vibration During Setting of Grout
Sponsored by ASBI, Florida DOT, and
Texas DOT

Dr. Andrea Schokker, Principal Investigator

Edwin Salcedo, Research Assistant
Jessica DeSalvo, Research Assistant

PENN STATE UNIVERSITY

 Oils for Temporary PT Corrosion
Protection
Sponsored by the Texas DOT
 Corrosion protection
 Degree of bond reduction

 Oils
– Testing those used in PT & potential candidates from the
metal working industry
– Water source and water content
– Application
 No water flushing of tendons
 Oils for Temporary PT
Corrosion Protection
 Corrosion Testing
– Electrochemical Evaluation (grouted)
– Ungrouted exposure testing

Outdoor exposure (through winter)

Humid exposure (controlled: 23 C, 96% RH)

Saltwater exposure (partial submersion)
 Bond (pull-out) testing
 Large scale bond testing
 List of Oils Tested
 Oil 1: Anticorit AQ 31
 Oil 2: Citcool Concentrate 33
 Oil 3: Cutting Oil NC 205
 Oil 4: Dromus ABD
 Oil 5: Emulsifiable Cutting Oil
 Oil 6: 5-Star Protective Coating
 Oil 7: Hocut 4284-B
 Oil 8: Hocut 795
 Oil 9: Lubrol 215 B
 Oil 10: Nox-rust 703 D
 Oil 11: Nox-rust 707
 Oil 12: Rheocrete 222+
 Oil 13: RustBan 310
 Oil 14: Rustphree 4746A
 Oil 15: Rust-Veto 342
 Oil 16: Rust-Veto FB 20
 Oil 17: Tectyl 810
 Oil 18: VpCI 377
 Oil 19: VpCI 389
 Corrosion Specimens

Type A:
Outdoor
Exposure
&
Humidity
Chamber

Type B:
Saltwater
Exposure
 Corrosion Ratings
 1- Excellent: As received from Manufacturer
 2- Very Good: No sign of corrosion or small rust spots
 3- Good: Small blisters, superficial but widely spread corrosion,
pitting is unusual
 4- Satisfactory: Small blisters, uniform corrosion or wide pitting in
small areas
 5- Fair: Blisters, Deep and/or wide pitting, interstitial corrosion
 6- Poor: Large blisters, trail of blisters no greater than two inches,
deep and wide pitting, pitting not present in all wires, interstitial
corrosion
 7- Very Poor: Large blisters, deep and wide pitting affecting over
70% of strand surface area, strong interstitial corrosion, visible
large areas of steel section loss
 Corrosion Performance
Finalrating
Corrosion Corrosion
afterRating Stage
6 months exposure

7
6
Intensity

5
Rating

4
3
Corrosion

2
1
0
l
ro
nt
Co

Specim e n Type

Environment 1
Outdoor Exposure Environment 2
Humidity Chamber Environment
Saltwater 3
 Exposure Duration & Intensity
 Corrosion onset and intensity varies with oil
type and environment
Oied Specimen Performance - O4
O4 Performance
4
C orrosion R ate

3
Environment 1
Environment 2
2 Environment 3
1

0
1 2 3 4 5 6

Time (Months)
Pullout Test Specimens
 O2 - Displacement Vs Load

0.4
Disp lacemen t (in )

0.3 O2-1 Good bond

O2-2
0.2 performance
0.1

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Load (kips)

O15 - Displacement Vs Load

0.3
D isp lacem en t (in )

O15-1
0.2
Poor bond O15-2

performance 0.1

0
0 0.25 0.5 0.75 1
Load (k ips )
 Pullout Test Results
(Oils with Corrosion Rating < 4)

Load at 0.1 in. Strand Slip

NO (5.33)

18 NO-R (5.33)
16 O 3 (3.83)
14 O3
Load (kips)

12 9.584 O 4 (3.00)
10 O4 O 13
NO O 5 O 17 O 10 O 13 (2.17*)
8 NO-R 6.500 5.826
16.328 4.839 4.513 3.648 O 16
6 13.861 O 5 (3.67)
2.789
4
O 17 (4.00)
2 69% 47% 42% 35%
0 O 10 (3.67)
@ 0.1 in. Strand Slip O 16 (4.00)
 Conclusions and Recommendations
 Multiple oils produced in the U.S. provide adequate corrosion
protection
 Bond Reduction From Emulsifiable Oils Vary From 30% to
97%
 Recommended oils for large-scale testing:
Oil Manufacturer Corrosion Rating* Bond Reduction

O3: Cutting Oil NC 205 Citgo 3.83 31%

O4: Dromus ABD 201 Shell/Texaco 3.00 53%

O13: Rustban 310 Esso (Europe) 2.33 58%

O5: Emulsifiable Cutting Oil Shore Chemical 3.67 65%

*Saltwater Exposure for 6 months

 Influence of Vibration During
Setting of Grout
Sponsored by ASBI and the Florida DOT

 Objectives
– Determine if shock and vibration from construction
equipment loads has a detrimental effect on grouts
during set
– Recommend construction traffic limitations if necessary
to avoid adverse effects on grout
 Bleed Testing
 30 Hz
– suggested by Florida DOT based
on vibration readings from pile
driving – will represent higher
frequencies than tendons are
likely to see
 5 Hz
– More representative of actual
vibration in structure
 Plain grout to investigate
“worst case”
 Prepackaged grout to
investigate industry standard
 Plain grout at 30 Hz
(selected results)
3.5
V-Control
3.0 V hours 1-9
V hours 3-9
V hours 5-9 Grouts with
2.5 V hours 7-9
Bleed Level (in)

early age
2.0 vibration

1.5

1.0

0.5 Control: no vibration

0.0
0 2 4 6 8 10
Time (hrs)
 Summary of Bleed Testing
 Plain grouts
– Increased bleed with early age vibration at 30 Hz
– Increased set time with vibration prior to set
– Little change in bleed with vibration at 5 Hz
 Prepackaged grout
– Very little change in bleed with vibration at 30 Hz
– No change in bleed with vibration at 5 Hz
 Test Program
 Bond Effects
– Prepackaged grout
– 5 Hz with 10 minutes vibration per hour
– Varied vibration times
– Standard PTI pull-out test
 Pull-out Test Data
Control Specimen - Load vs. Displacement
0.35

0.3
Displacement (in)

0.25

0.2

0.15

0.1

0.05

0
0 5 10 15 20
Load (kips)
 Vibration Results
Vibrated 10 minutes each hour
25
Set time 11 hours

20
Load at 0.1" slip (kips)

15

13% reduction
34% reduction
10

0
Control 0-11 hrs 4-11 hrs 8-11 hrs

Vibration Interval
 Vibration Results
Vibrated 10 minutes at start and finish of interval
25
Set time 11 hours

20
Load at 0.1" slip (kips)

15

10

0
Control 9-10 hrs 10-11 hrs 11-12 hrs 12-13 hrs
Vibration Interval
 Summary of Bond Testing

 Vibration during the first few hours after

grouting may influence bond
 Multiple vibration incidents cause the most
influence

 Bond reduction minimal if vibration limited

until close to set time
 Recommendations
 Limit vibration (construction traffic) for four hours
after grouting
– unless testing on the specific grout shows adequate bond
at earlier ages
– if limitations on construction traffic to four hours cause a
scheduling problem, a case-by-case basis can be used to
determine whether this reduction is critical for the
application

 Construction traffic should be limited for 24 hours

when a plain grout is used