QC/QA Process & A354 BD Rod Testing Program

QC/QA Process &QC/QA Process &A354 BD Rod Testing Program

Bahjat Dagher, PE

Caltrans Engineering ServicesCaltrans Engineering ServicesCaltrans Engineering Services

j gMaterial Engineering & Testing Services

O tliOutline• Section I: Introduction• Section II: Fabrication Process• Section III: Quality Assurance• Section IV: Testing Program for SAS Rods

Caltrans Engineering ServicesCaltrans Engineering ServicesCaltrans Engineering Services2

S ti I I t d tiSection I: Introduction

• 2,306 anchor rods• 17 groups of rods

Top of Tower

Top of W2 East Cable Band

East Saddle Anchorage

Top of E2


Bottom of Tower

3

A354 Gr BD Anchor RodsAnchor RodsSAS


A354 Gr BD Anchor Rods

96 Rods224 Rods320 Rods

Anchor RodsSAS

274 Rods 25 Rods 108 Rods336 Rods

192 Rods96 Rods

274 Rods 25 Rods 108 Rods336 Rods

4 Rods90 Rods 388 Rods 36 Rods

24 Rods 43 Rods32 Rods 18 Rods


A354 Gr BD Anchor Rods

0.6 Fu0.7 Fu0.7 Fu

Anchor RodsSAS

0 32 Fu 0 68 Fu 0 5 Fu0 4 Fu

0.7 Fu0.7 Fu

0.32 Fu 0.68 Fu 0.5 Fu0.4 Fu

0.1 Fu0.1 Fu 0.48 Fu 0.37 Fu

0.16 Fu 0.1 Fu0.1 Fu 0.2 Fu


S ti II F b i ti PSection II – Fabrication Process


F b i ti PFabrication ProcessSteel Mill

• Shipment of material from the mill to the fabricator

Steel Mill


F b i ti PFabrication ProcessSteel Mill Heat

T t t

• Quenched & tempered• Oven heated

Steel Mill Treatment

• Induction coil

• Hardness, strength, grain size, other properties


F b i ti PFabrication ProcessSteel Mill Heat

T t t Threading

• All rod threads were cut with the exception of:• E2 Bearing Top Rods (B1, B2, B3, B4) – Rolled

Steel Mill Treatment Threading

g p ( , , , )• PWS Anchor Rods (80%) – Rolled • Tower Saddle Tie Rods – Rolled • B14 Cable Band Anchor Rods Rolled• B14 Cable Band Anchor Rods – Rolled


F b i ti PFabrication ProcessQC

T tiSteel Mill Heat T t t Threading

• Mechanical Properties per ASTM A354 • MT performed on rods specified by CCO 91

TestingSteel Mill Treatment Threading

MT performed on rods specified by CCO 91


F b i ti PFabrication ProcessQC

T tiSteel Mill Heat T t t Threading Galvanizing

• Dry blast cleaned to a near white finish (SP-10) prior to galvanizing per ASTM A123

TestingSteel Mill Treatment Threading Galvanizing


S ti III Q lit ASection III – Quality Assurance


Q lit AQuality Assurance Audit

• Facility audits in 2007 and 2008• Audit performed by Caltrans

Audit

Audit performed by Caltrans• Final results of audits: Pass


Q lit AQuality AssuranceAudit Source

I ti

• In-process inspection• Thread dimensional verification

Audit Inspection

Thread dimensional verification• Magnetic Particle Testing


Q lit AQuality AssuranceAudit Source

I tiDocument V ifi ti

• Document verification• Certificate of Compliances

Audit Inspection Verification

Certificate of Compliances• Mill Test Reports• QC test results


Q lit AQuality AssuranceQA

S liAudit Source I ti

Document V ifi ti

• Defined in state letter dated July 14, 2008• One full size sample per heat

SamplingAudit Inspection Verification

One full size sample per heat• Two reduced size samples per heat



S liQA

T tiAudit Source I ti

Document V ifi ti

• Tests performed:• Full size tension

Sampling TestingAudit Inspection Verification

Full size tension• Reduced section tension• Hardness• Coating thickness



S liQA

T tiMETS

R lAudit Source I ti

Document V ifi ti

Orange Tag• Material conforms to

Blue Tag• Material does not conform

Sampling Testing ReleaseAudit Inspection Verification

Material conforms to contract requirements

Material does not conform to contract requirements but accepted as fit for purpose


QC/QQC/QA Documentation


Section IV – Testing Program for SAS R dSAS Rods


T ti PTesting Program

• Contract Specified QC/QA• Tensioning & Monitoring of Remaining Rods

T t I Fi ld H d T t (i it )• Test I – Field Hardness Test (in-situ)• Test II – Laboratory Test• Test III – Full Size Test• Test III – Full Size Test

• Test IV – Stress Corrosion Test (Dr. Townsend)( )• Test V – Incremental Step Loading Test (Dr. Raymond)• Test VI – Slow Rate & Sustained Loading Test (Dr. Gorman)


Tensioning & Monitoring of R i i R dRemaining Rods

• 2010 anchor rods tensioned in April 2013• 10 Rods were monitored using Acoustic Emissions

N k d t t d• No cracks were detected


T t I Fi ld H d T t (i it )Test I: Field Hardness Test (in-situ)

• UCI Test Method• 1,361 Rods tested on bridge


224 Rods287 Rods

Test I:

270 Rods 20 Rods 20 Rods

138 Rods96 Rods

Field Hardness


226 Rods 36 Rods

12 Rods16 Rods 8 Rods



• Performed in-situ• Cleaned from oil, grease, and rust

T f l i i d b i di• Top surface galvanizing removed by grinding



• Top surface sanded to achieve profile 15 µm or less• Roughness verified with a profile meter



• Multiple points on each rod• Multiple readings at each point

V ifi d i t lib t d• Verified against a calibrated block



43

45

35

37

39

41

29

31

33

35

25

27

4” Rod


T t II L b t T tiTest II: Laboratory Testing

• Hardness Test• Spectrochemical Analysis

Ch I t T t (if il bl )• Charpy Impact Test (if available)


7 Rods12 Rods

Test II:Laboratory


Laboratory Testing


6 Rods 3 Rods

2 Rods 1 Rod


T t II L b t T ti S lTest II: Laboratory Testing - Samples

Sample Sample

19

Sample76 mm

18519 mm 185 mm


T t II R k ll C H dTest II – Rockwell C Hardness

• 12.5 mm thick sample• Test at 3 mm increments and one location at R/2 in

each quadranteach quadrant

Hardness tests at


3mm increments and one in each quadrant, Typ

33

T t II R k ll C H dTest II – Rockwell C Hardness

• Average hardness values for PWS Anchor Rods and Tower Saddle Tie Rods

36.038.040.0

ness

Average (Item 7)

36.038.040.0

ness

Average (Item 8)

26 028.030.032.034.0

Roc

kwel

l C H

ard

FieldL b t 26 0

28.030.032.034.0

Roc

kwel

l C H

ard

FieldL b t

24.026.0

0.000 0.500 1.000 1.500 2.000 2.500 3.000 3.500

R

Location (in.)

LaboratoryASTM Req. 24.0

26.0

0.000 1.000 2.000 3.000 4.000

R

Location (in.)

LaboratoryASTM Req.


“M” Sh C I ti ti“M” Shape Curve Investigation

• Tilting of sample during testing of the edges• Testing of longitudinal samples

Si il lt b d• Similar results observed


“M” Sh C I ti ti“M” Shape Curve Investigation

• Decarburization• ASTM F2328 tests performed• No evidence of decarburization• No evidence of decarburization

• Microstructural ExaminationMicrostructural Examination• At the HRC indentations• In progress


T t II Ch i l A l i

• Spectrochemical analysis

Test II – Chemical Analysis

• Spectrochemical analysis• Min. 3 samples per rod: Center, perimeter, R/2• All tested rods met A354 BD chemical requirementsAll tested rods met A354 BD chemical requirements


T t II Ch I t T tTest II – Charpy Impact Test

• 10 x 10 specimens• 3” to 4” Rods – 6 specimens along circumference

2” R d 3 i l i f• 2” Rods – 3 specimens along circumference 6 specimens total


T t II Ch I t T tTest II – Charpy Impact TestData points are averages of several tests from multiple samples

52 53

50

60

40F 70F

Data points are averages of several tests from multiple samples

3739 39

32

38 37 41 42

36 40

t-lbs

27

17 1821

16

24

20

30ft

13

0

10


Item #3 Item #4 Item #7 Item #8 Item #9 Heat 1 Item #9 heat 2 Item #12 Item #13 Item #1540F 36.9 27.3 39.0 16.9 52.3 13.0 39.1 31.7 17.870F 37.6 36.7 40.8 20.8 52.7 16.0 41.8 36.3 23.7

0

39

T t III F ll Si T i T ti

• Full Size Tension Test

Test III: Full-Size Tension Testing

• Full-Size Tension Test• Reduced-Size Tension Test• Rockwell C HardnessRockwell C Hardness• Knoop Micro-Hardness• Charpy Impact Test• Metallurgical Analysis • Microstructural Analysis• Galvanization Chemistry


2 Rods4 Rods

Test III:

1 Rod 1 Rod

4 Rods

Full Size Testing

1 Rod 1 Rod

1 Rod 1 Rod

1 Rod


T t III F ll Si T i T tTest III – Full Size Tension Test

• Loaded to failure at a constant rate.


T t III F ll Si T i T tTest III – Full Size Tension Test

• Full size samples selected from 8 groups for tension

170

160

165

170

s ks

i GROUP 2

GROUP 3

GROUP 4

150

155

sile

Str

ess GROUP 4

GROUP 7

GROUP 8

GROUP 11

135

140

145

Tens GROUP 12

GROUP 14


T t III F ll Si T tiTest III: Full-Size Testing

• Specimens are extracted from a full size rod.

Tensiles

mCp

Charpies Che

mH

RC

Kno

o


T t III R d d Si T i T tTest III – Reduced Size Tension Test

• Reduced size tension tests / .505


T t III R d d Si T i T tTest III – Reduced Size Tension Test

165

170

155

160

165

Stre

ss k

si

Group 2Group 3Group 4

140

145

150

Tens

ile S Group 7

Group 8Group 12

135

140


T t III M t ll i l A l iTest III – Metallurgical Analysis

• Metallurgical and Fracture Analysis• Scanning electron microscope (SEM)


Test III – Metallurgical AnalysisR i 1Region 1

• Fracture Initiation areas indicate ductile tearing as a result of tensile overload.



• Propagation area shows fracture features of both cleavage & ductility.



• Final Fracture areas show dimpled ductile features.


T t III Mi t t l A l iTest III – Microstructural Analysis

• Inclusions and banding in steel


QUESTIONSQUESTIONS


Documents

QC/QA Process & A354 BD Rod Testing Program