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com

cable capacity because it changes the cross-

Newsletter # 007 ~ 01 Jan 2020 sectional area of the cable wires rapidly. Some
of these methods of corrosion are not likely to
THE IMPORTANCE OF ACID PICKLING occur in PT anchorage systems. Stress corrosion
for production of PCStrands. cracking is primarily a concern for very old PT
anchorages where the annealing process created
- By Sanjay A, GSS – Technical Director
susceptibility to failure due to increased
Numerous studies and research over the hydrogen [6]. Likewise, crevice corrosion and
years have raised enough concerns on effects corrosion due to fungal and mold growths in the
of corrosion in PC Strands. PT grease are generally considered less of a
deterioration concern than that of pitting
In a detailed study conducted by Richard, corrosion. In most cases, corrosion is an
Barry and Robert – working for the US Army electrochemical reaction and acts in cells like
Engineer R&D Centre, reported in their batteries, where cathodes corrode and transfer
research article dated 21Mar2016, it is clearly electrons to anodes.
established Corrosion in the Steel Strands is
amongst the chief causes
for strength reduction Corrosion of strand anchorages
and subsequent failure occurs in many forms and is
of the structures. influenced by several factors
‫الوقاية خير من العالج‬ such as temperature, oxygen
Excerpts of the concentration, water presence,
research: salts and/or acids present, grout
PC strand ‫ اآلثار السلبية لتآكل ال‬electrical resistance, pH,
1.2. Corrosion Damage of ً ‫ الموجود في الھياكل الخرسانية غالبا‬microbial activity, and scaling
Embedded Strands. The tendency. From the number of
‫ال‬ ‫أنه‬ ‫ذلك‬ ً ‫ عاما‬١٢-١٠ ‫ ما يظھر بعد‬these factors, it can be deduced
corrosion process of
prestressed steel tendons .‫بديل عملي عن الصقل الحمضي‬ that any method chosen to
consists of two phases: protect the tendons must be able
to protect the strands from a
Corrosion initiation, myriad of these influences at all
usually occurring before “.. Prevention is always better times. In practice, older
the cable is embedded, than cure... The unbonded tendons are protected
and corrosion ill-effects of Corrosion in PC- by anticorrosive grease
propagation, informing surrounding the cable in a
Strands going inside a polymer sheath, which is then
the rate of corrosion, Concrete Structure usually
which will determine the surrounded by a protective
life span of the cable [3]. takes about 10-12 years before grout. In even older
it surfaces out. installations, only a protective
Corrosion actually There is no real substitute of grout may be present around the
initiates when the cable with no protective plastic
Acid pickling ...” or metal PT duct. Due to
protective oxide film that
has formed around the steel member is proximity to environmental moisture ingress,
compromised by a chloride concentration that stress concentration at the anchor wedges
exceeds a threshold or by lowering the pH of the themselves, and the absence of any redundant
grout [4]. At least seven types of corrosion protection at the grip mechanism, the anchor-
mechanisms are involved in prestressed head region tends to be a region of high probable
anchorage corrosion: pitting corrosion; uniform failure within the cable PT system. Macro cell
corrosion; stress corrosion cracking; hydrogen corrosion as opposed to micro cell corrosion is
cracking; crevice corrosion; fretting corrosion; another major concern of PT cable corrosion.
and fatigue corrosion [5]. All are invasive to the The larger macro cell corrosion cells are more
material. Pitting corrosion has the most effect on likely to occur between regions where the
 GulfSteelStrands.com

embedded part of the cable serves as the cathode

and the grout interface region near the anchor
head serves as the anode [4]. The macro cells
conduct current along a larger reach of the
anchor.

If themacrocell current density is the same as a

micro cell, the micro cell corrosion damage will
be greater, having the same volume of damage
over a more localized area of the cable.

One of the primary causes of tendon failure in

anchor assemblies is the failure of the grout
protecting the tendons.
Voids occurring at the time of construction
allow moisture to penetrate into the PT duct and
corrode the cables. The absence of the grout also
eliminates the high-pH surface passivation,
which serves to protect the cable. Various
studies on tendon-failure cases in bridges also
indicate that the presence of chlorides in grouts
is a major contributor to tendon failure [7].
Pipelines, boiler tubes, and storage tanks lend
themselves well to the development of corrosion
models for condition estimation. In these
structures, the properties and conditions of the
materials in contact with the steel are easily
quantifiable and the systematic attack on the
material can be reasonably estimated. Even
though we know the various mechanisms that
affect or facilitate deterioration of PT cables,
these mechanisms tend to occur randomly and
not systematically.
Without direct access, any estimation of
corrosion in PT cables can have a significant
degree of uncertainty…..
Similar to studies made by US Army
Engineers, in a detailed research conducted
by Dr. Bishal Parajuli for University of
Toledo (2016) – the research paper studies
the Hidden corrosion in Prestressing Strands.

Unlike bridges where ocean or brackish

saltwater and deicing salts produce
environmental-based increases in concrete and
grout chlorides, navigation structures are not
generally expected to suffer increased chloride
levels with time. In general, if high-grout
chlorides are present in navigation structures, it
would be due to problems occurring in the initial
batching operations.
Loose scales are one of the chief causes of
Corrosion – Loose scales which are not really
removed completely by Mechanical descaling
process. Over passage of time, the corrosion
eventually progresses reducing the strength

of the Beams – eventually leading to Beam
failure.
Common misconception: Concrete is thought
to be a reliable protection against the
corrosion. But in reality, it never was. It is
quite ironic that the concrete itself acts a
medium of corrosion reaction and it provides
favorable condition for the corrosion to take
place. The micro-cracks, heterogeneity and
pores of concrete make the corrosion
inevitable.
During hot production of Steel, formation of
Oxide layer (scales) is an unavoidable
phenomenon. There are normally a minimum
of 3 layers of compact adherent oxide scales
formed during hot rolling.
So, we at GSS – in our effort, to ensure, that
the Strands withstand corrosion resistance to
the maximum extent possible, undertake
ACID PICKLING of our raw materials. Most
of our competitors, in order to save costs, do
not undertake Acid Pickling.
You may ask a question: How is Acid pickling
a better way to mechanical descaling??
Various researchers in the last decades have
made extensive comparisons between Acid
Pickling and Mechanical descaling.
Alternate methods to Acid Pickling, are
surely much cheaper but none as effective as
Acid Pickling. Some of the alternates, as
follows, are herein discussed.
Abrasive Blasting – commonly used cheaper
practice. Dry abrasive blasting can be used to
remove most of the surface oxides, but cleaning
effect is not usually as good as with pickling.
Different media can be used to produce different
surface smoothness. Silica sand was broadly
used, but the health hazard of dust has limited its
usage. Media such as steel grit, cut wire and
aluminum oxide grit are options with less dust
and good cleaning efficiency. Softer alternatives
such as crushed nut shells, glass beads, dry ice
and sodium bicarbonate are used to remove
softer impurities such as old paint layers and are
not used to remove an oxide layer. Round shot
GulfSteelStrands.com
style media used to produce smoother or peened
surfaces can cause some contaminants to be
trapped in the surface as shown in the below
figure and should not be used to remove an
oxide layer.
Contaminant trapping mechanism when using shot style blast media.
Abrasive media can be used with water to
provide better cleaning efficiency. Water with
additives removes grease and salts while
blasting media removes oxides.
Corrosion inhibitors can also be used to prevent
flash rusting. Wet abrasive blasting requires
special equipment and is not commonly used.
Grinding
Grinding is usually used just to remove welding
defects and scratches to provide smoother
surfaces. If rough grinding equipment is used,
finer equipment should be used afterwards to
ensure a smooth surface which is better for
corrosion resistance.
Wire Brushing.
Wire brushing can be used to remove most of
the impurities from the surfaces. Part of the scale
remains in the surface roughness. Wire brushing
does not cause serious roughening of the
surface. Complex parts are hard to clean using
wire brushes. Special equipment such as pipeline
pigs is available to clean pipes. Brushing can be
used to break the oxide layer and that way
increase pickling efficiency.
Water Jetting
Ultrahigh-pressure water blasting (220 MPa) is
capable of removing scale but not the entire
oxide layer. If complete removal of oxide is not
necessary, water jetting is fast and environment-
friendly. Special equipment that is available only
from very few vendors is required. Lower
pressures can be used to remove paint and salts.
Thermal Cleaning
Oxygen acetylene torch or oven can be used to
remove grease, paint, scale and rust with the

help of machine wire brushing. This method is
usually used with old greasy parts. Steam can be
used to remove scale and debris from surfaces.
Oxide is not removed completely using thermal
cleaning methods.
To conclude Acid Pickling seems to be most
practical best method to remove Oxide scale,
despite the fact it is quite more costly owing
to strict monitoring of EPA requirements.
For the same reason, Acid pickling is the usual
practice prior to Zinc Galvanization.
The main purpose of the GSS wire rod
preparation line is to ensure maximum
removal of the highly abrasive oxide layer
from the surface of the wire – to ensure that
no Oxide scale finds it way into the finish
Strand – It is the oxide scale where hidden
corrosion inhabits itself.
Drawing wire that still has an oxide layer on
its surface means that the scale will be
embedded into the wire and cause breakages
or premature failure as well as leading to
eventual corrosion once cast into Concrete.
At GSS – we not only Acid pickle our raw
material (intended for production of PC
Strands)... but coat it with Phosphate and
Lime, after the Pickling process, in order to
ensure that no further oxides are formed
after the removal of Oxide scales in the acid
pickling process.
The best way to avoid / minimize the risk
of corrosion is to prevent it. Prevention
should start right on the Wire rod which
goes into production of PC Strands.
Bibliography
[1] A. Azizinamini and J. Gull, “Improved inspections
techniques for steel pre-stressing/post tensioning strand,”
FDOT Contract BDK80 977-13, Final Report-Volume 1,
Florida International University, Miami, University Park,
Miami, Fla, USA, 2012,
http://www.dot.state.fl.us/research-center/Completed
Proj/Summary MNT/FDOT-BDK80-977-13-rptvol1.pdf.
[2] I. Bartoli, S. Salamone, R. Phillips, C. Nucera, and F.
Scalea, “Health monitoring to detect failure of Prestressing
(PS) cables in segmental box-girder bridges,” Tech. Rep.
SSRP 0906, Department of Structural Engineering,
University of California, San Diego, San Diego, Calif, USA,
2012.
GulfSteelStrands.com
[3] R. M. Ebeling, B. C. White, J. A. Evans, R. W. Haskins,
and E. L. Miller, “Corrosion induced loss of capacity of post-
tensioned seven wire strand cable used in multistrand
anchor systems installed at corps projects,” Tech. Rep.
ERDC/ITL TR-16-4, Engineering Research and
Development Center, Vicksburg, Miss, USA, 2016.
[4] S.-K. Lee and J. Zielske, “An FHWA special study: post-
tensioning tendon grout chloride thresholds,” Federal
Highway Administration Report FHWA-HRT-14-039,
Research, Development, and Technology Turner-Fairbank
Highway Research Center, McLean,Va, USA, 2014.
[5] T. Hopwood and J. H. Havens, “Corrosion of cable
suspension bridges,” Research Report UKTRP-84-14,
Kentucky Transportation Research Program, College of
Engineering, University of Kentucky, Lexington, Ky,
USA,1984: http://www.ktc.uky.edu/files/2012/09/1984-
Corrosion-of-Cable-Suspension-Bridges-UKTRP-84-14.pdf.
[6] M. S. Darmawan and M. G. Stewart, “Effect of pitting
corrosion on capacity of Prestressing wires,” Magazine of
Concrete Research, vol. 59, no. 2, pp. 131–139, 2007.
[7] D. Trejo, R. G. Pillai, M. B. D. Hueste, K. F. Reinschmidt,
and P. Gardoni, “Parameters influencing corrosion and
tension capacity of post-tensioning strands,” ACIMaterials
Journal, vol. 106, no. 2, pp. 144–153, 2009.
[8] R. D. Moser, High-strength stainless steels for corrosion
mitigation in prestressed concrete: development and
evaluation [Ph.D. thesis], Georgia Institute of Technology,
Atlanta, Ga, USA, 2011.
[9] E. Dougherty, An Introduction to Morphological Image
Processing, SPIE Optical Engineering Press, Bellingham,
Wash, USA, 1992.
[10] R. M. Ebeling, R. W. Strom, J. E. Hite, R. W. Haskins,
and J. A. Evans, Assessing Corrosion Damage and
Corrosion Progression
in Multistrand Anchor System in Use at Corps Projects,
ERDC TR-13-3, Engineering Research and Development
Center, Vicksburg,Miss, USA, 2013,
http://acwc.sdp.sirsi.net/client/default/
index.assetbox.assetactionicon.view/1028160;jsessionid=75
5CB8E9AB17854C8D2B54CE9D0D9FFC.enterprise-
15000?rm=ENGINEER+RESEA0%7C%7C%7C1%7C%7C
%7C0%7C%7C%7Ctrue.
[11] Rashid, Y. R. (1968). Ultimate strength analysis of
prestressed concrete pressure vessels. Nuclear engineering
and design, 7(4), 334-344.
[12] Song, G., & Shayan, A. (1998). Corrosion of steel in
concrete: causes, detection and prediction: a state-of-the-art
review (No. 4).
[13] Xia, J., & Jin, W. L. (2014). Prediction of Corrosion-
Induced Crack Width of Corroded Reinforced Concrete
Structures.
 GulfSteelStrands.com

At GSS – your PC Strands are Pickled in
H2SO4 (Sulfuric Acid) in an environment
friendly process under strict norms prescribed by
EHS Authorities of UAE Govt.
To ensure zero oxidation, Wire rod Coils are
further Phosphated and then coated with Borax.
The pickling sequences are managed by
sophisticated SCADA systems that operate two
rigid automatic cranes and optimize coil
movements in order to reduce process time to a
minimum.

GSS has a dedicated line suitable for large

productions and maximum flexibility in the
coating.

Acid pickling tanks

Dip rinse tanks ( hot and cold)
Dynamic rinse tank
Phosphate activation tank
Phosphate coating tank
Borax coating tank At the current price index, the Acid Pickling
Lime coating tank process by itself costs around $50 pmt more
over the mechanical descaling process.
There is no real effective substitute of Acid
Pickling process for the production of PC However, at GSS – we spend this money, to
Strands. ensure that construction made with GSS PC
Strands never fails.
Unlike the Mechanical descaling / Abrasive
blasting process, only Acid Pickling ensures
100% removal of Oxide layers.

GSS boasts of a complete line to treat Waste

water and to recover acid.

GSS strictly follows all applicable environment

norms prescribed by EHS Authorities.