ML20129F633

Anchor Head Investigation, Final Rept

ML20129F633
Person / Time
Site:	Farley
Issue date:	07/10/1985
From:	Budinger D, Henger G, Noe P INLAND STEEL CO., PRECISION SURVEILLANCE CORP. (FORMERLY INRYCO, INC.)
To:
Shared Package
ML20129F600	List: ML20129F596 ML20129F611 ML20129F633
References
NUDOCS 8507170417
Download: ML20129F633 (71)

Text

O O

e INTER-CCWAJNICATION INLAND STEEL COMPANY IMIANA HARBOR WORKS I

DATE MARCH 27, 1985 TO R.J.GLATTHORN TITLE SUPERINTEPGENT PROM

/

DEPT OPERATING TECtedOLOGY

'G.W.HENGER d TITLE ASST. SUPERINTEWENT DEPT.

OPERATING TECtedOLOGY FILE REF. OMO FILE NO. 19875 COPIES TO J.HEISE P.P.NDE H.HENDRICKSON-8 H. PRES $ WALLA N. MONACO SusaECT INRYCO POST TENSIONING DIVISION JOSEPH M. FARLEY WCLEAR PLANT, UNIT NO.2 ANCHOR HEAD INVESTIGATION l

OMD INVESTIGATION NO. 19075 - FINAL REPORT IN JAW ARY OF 1985 SERVICE FAILURES WERE DISCOVERED ON TWO FIELD ANCHOR HEADS INSTALLED ON THE CONTAIpaIENT BUILDING OF THE JOSEPH M.

FARLEY WCLEAR PLANT, IAdIT NO.

2 LOCATED AT DOLTON, ALABAMA.

THE PLANT, WHICH HAS BEEN IN SERVICE FOR APPROXIMATELY I

SEVEN YEARS, IS OPERATED BY THE ALABAMA POWER COMPANY.

THE ATTACHED REPORT SY MR. D.E.BUDINGER COVERS THE FAILURE ANALYSES ANO METALLURGICAL EVALUATION OF THESE TWO ANCHOR HEADS. HV 018 ANO HV 038.

IN AD0! TION, THE REPORT COVERS THE NETALLURGICAL EVALUATION OF FOUR OTHER ANCHOR HEADS, letICH WERE REMOVED FROM THE CONTAIp90ENT BUILDING BUT HAD NOT FAILED, THE METALLURGICAL EVALL'ATION OF ONE GREASE COVER AND THE CHEMICAL ANALYSES OF SEVERAL GRCASE SAMPLES.

MR. BUDINGER'S CONCLUSIONS ARE 85071704178507h48 PDR ADOCK 0500 8

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4 PAGE 2 I

1.

THE FAILURE OF THE ANCHORAGES WAS DUE TO THE IN-SERVICE EMBRITTLE-MENT AS IDGICATED BY SIIB4IFICANT AMOUNTS OF INTERGRAMJLAR SEPARATION (IGS) SEING EVIDENT ON THE FRACTURE FACES OF THE ANCHORAGES. THE CONCLUDED DSRITTLING AGENT IS HYDROGEN, tMICH RESULTS IN HYDROGEN STRESS CRACKING (MSC).

i 2.

THE MAJOR SOURCE OF THE HYDROGEN WAS THE PRESENCE OF WATER IN CONTACT WITH OR ADJACENT TO THE ANCHDR HEADS WITHIN THE GREASE COVERS. ATOMIC OR NACENT HYDROGEN WAS GENERATED BY THE CORROSION REACTIONS OF IRON AfC ZINC IN THE PRESENCE OF WATER. THE FAILURES WOULD 867 MAVE OCCURRED WIT) GUT THE PRESENCE OF WATER.

4 3.

THE SOURCE OF TDE WATER, WHICH WAS HEAVILY CONTAMINATED WITH CATIONS AND ANIONS, IS THE ON-SITE ENVIROSSIENTAL CONDITIONS.

4.

BOTH THE ANCHORAGE TEMON HDLES AND THE GREASE COVER INTERIOR i

SHOWED EVIDENCE THAT ACTIVE CORROSION HAD TAKEN PLACE.

S.

NEITHER CRACKING IfeUCED ON STRUCTURAL TESTING AT THE UNIVERSITY OF ILLINOIS NOR THE INLAPS LABORATORY-CREATED FRACTURES ON TENS!LE OR IMPACT SPECIMENS SHOWED IGS. THIS INDICATES THAT THE EMBRITTLING SPECIES IS ND LONGER PRESENT Afc ELIMINATES TEMPER EMBRITTLEMENT AS THE SOURCE OF THE FAILURES. OTHER POSSIBLE SOURCES OF THE IGS WERE ELIMINATED BY THE COMBINATION OF SCAfmING ELECTRON MICROSCOPY AND MECHANICAL TESTING.

THE METALLURGICAL EVALUATION IPWICATED THAT THE ANCHORAGES HAD HIGHER STRENGTHS SUT DUCTILITIES WITHIN THE RANGE OF PREVIOUSLY TESTED #LUMIMal GRAIN REFINED FIELD ANCHOR HEADS. THE HIGHER

)

STRENETHS WOULD pmT HAVE RESULTED IN THE SUBJECT FAILURES, POWEVER, i

~

WOULD INCREASE THE SUSCEPTIBILITY TO HSC AND IGS. THE ANCHORAGES MET THE HARDNESS REQUIREMENTS OF THE INRYCO SPECIFICATION AND THE CHEMICAL REQUIREMENTS OF THE ASTM AND INRYCO SPECIFICATIONS.

THE MICR0 STRUCTURES AND MICROCLEANLINESSES WERE AS EXPECTED FOR THE STEEL GRADE Ape COPCITION.

RETEMPERED ANCHORAGES INDICATED THAT THE HEADS WERE HEAT TREATED AS SPECIFIEU.

1

I o

O A

PAGE 3

'i FINALLY, THE FOLLOWING REC 00eIDCATIONS WERE NADE:

1.

ELIMINATION OF WATER IN THE POST TENSIONING SYSTEM IS ESSENTIAL FOR THE ELIMINATION OF THE RECURRENCE OF SIMILAR SERVICE FAILURES.

THE AMOLMT OF WATER THAT CAN BE TOLERATED CAN NOT BE DETERMINED WITH ANY CERTAINTY.

2.

IF THE WATER CAN MIT BE ELIMINATED. THEN THE ANCDWRAGES SHOULD BE INSPECTED AT SONE INCREASED FREQUENCY TO INSURE AGAINST FAILURES i

AND THE COLLECTION OF EXCES$1VE AMOUNTS OF WATER. VERTICAL TENDONS, DUE TO TMIR ORIENTATION, SHOULD BE THOROUW4LY EXAMINED FOR WATER.

3.

CURRENT VISUAL INSPECTION PftOCEDURES WILL NOT DETERMINE IF THE ANCHDRAGE IS CRACKED IN THE CENTER OF THE HONEYCOMB AT THE SHIM FACE. OETENSIONING AND MAGNETIC PARTICLE THSPECTION ARE NECESSARY TO DETERMINE IF SUCH CRACKING IS PRESENT.

4 4.

THE STRENGTH LEVELS OF THE ANOCRAGES SHOULD BE LOWERED IF POSSIBLE WITHIN THE SCOPE OF THE ORIGINAL DESIGN. WHILE THIS WILL REDUCE THE SUSCEPTIBILITY TOWARD HYDROGEN STRESS CRACKING (HSC), IT DOES NOT PRECLUDE THE OCCURRENCE OF HSC. DETERMINATIDN OF THE OPTIMUM STRENGTH LEVELS IS OUTSIDE THE SCOPE OF THIS INVESTIGATION.

PPN/R-SCRIPT I

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O O

A INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE I LIST OF TABLES TABLE 1 - METALLURGICAL TEST DATA ON ANCMDR MEAD HV 018 TABLE 2 - METALLURdICAL TEST DATA ON ANCHDR HEAD HV 038 TABLE 3 - METALLURGICAL TEST DATA ON ANCHOR HEAD HV 027 TABLE 4 - METALLURGICAL TEST DATA ON ANCHOR HEAD HV O28 TABLE 5 - METALLURGICAL TEST DATA ON ANCHOR HEAD HV 039 TABLE E - NETALLURGICAL TEST DATA ON ANCHOR HEAD HV 049 APPENDIX A - INLAND CHEMICAL DEPARTMENT GREASE ANALYSIS OF V-17 APPENDIX B - INLAND CHEMICAL DEPARTMENT GREASE ANALYSIS OF V-21 APPENDIX C - SUBURBAN LASDRTORIES, INC., GREASE ANALYSIS 1

l l

l

O O

P A

i i

INRYCO POST TENSIONING OIVISION - INVESTIGATION NO. 19975 PAGE II LIST OF FIGURES FIGURE 1 SKETCH OF TEW ON LOWER E W COMPONENTS FIGURES 2A-C POSITION OF TESTING ON ANCHORAGES FIGURE 3 AS-RECEIVEO FIELD FAILURE ON HV 016 FIGURES 4A-B FRACTOGRAPH OF HV 015 FRACTURE WITH OVERLAY FIGURE S FRACTOGRAPH OF HV 018 FRACTURE WITH OVERLAY FIGURE 8 FRACTOGRAPH OF HV 015 FRACTURE WITH OVERLAY FIGURE 7 AS-RECEIVEO FIELD FAILURE ON HV 038 j

FIGURE 8 FRACTOGRAPH OF HV 038 FRACTURE i

FIGURE 9 FRACTOGRAPH OF HV 038 FRACTURE WITH OVERLAY FIGURE 10 FRACTOGRAPH OF HV 038 FRACTURE WITH OVERLAY FIGURE 11 FRACTOGRAPM OF HV 038 FRACTURE WITH OVERLAY FIGURE 12 FRACTOGRAPH OF HV 039 FRACTURE WITH OVERLAY FIGURE 13A PHOTOGRAPH OF INTERIOR OF V-21 GREASE COVER FIGURE 138 PHOTOGRAPH OF INTERIOR OF V-21 GRLASE COVER FIGURE 14A SEM PRACTOGRAPH OF IGS ON HV 016 i

FIGURE 145 SEN FRACTOGRAPH OF IGS ON HV 018 FIGURE 15A SEH FRACTOGRAPH OF IGS ON HV 038 FIGURE 158

, SEM FRACTOGRAPH OF IGS ON HV 038 i

FIGURE ISA SEM FRACTOGRAPH OF PRECRACK ON HV 039 FIGURE 168 SEH FRACTOGRAPH OF POST-CRACK ON HV 039

- - - - - -- - ~ 0

TABLE 1.

IlJL AND STEEL ME tat t tJc( *r4L LADORATORY METALLURGICAL TEST DATA Ota FARLEY UNIT NO. 2 APJCHUR f fE O HV O t 6 CHEMICAL ANALYSIS:

C MN P

S SI CU NI MO CR AS C8 V

TI At N

02 SN SB

.43

.97

.Old

.028

.24

.tG

.13

.22

.10

.016

.008

.01

.004

.018

.008 58 PPM

.01

.008 MICR0 ANALYSIS-CLE APJLitlESS (J-K RATING ON APPEARANCE )

AU-464. B2l1 CARBIDE MORPHOLOGY TEMPERED MARTENSITE MACRUANALYSIS:

SOUND KILLED STEEL llARONESS (SURFACE):

BHN 429-444 (HRC CONVERTED 45-47)

HRC ACTUAL 40-41 TEtJSILE PROPERTIES:

SAMPLE VIELD+

1 ENSILE TOTAL REDUCTI0ta ELASTIC TEST STRENGTil STRENGTH ELONGATION IN AREA RATIO DIREC110N GAUGE IkSI)

(KSI)

(% IN 2")

(%)

YS/TS T R AtJSVE R SE

.503*

163.G 201.3 14.0 18.6 0.81 TRANSvFRSE

.498 168.2 198.5 8.0 13.9 0.R5 L 0tJGI TilOIN A L

.498 174.6 206.2 13.iO 35.9 0.85 LONGITUDINAL

.499 169.2 200.2 1 3.40 J5.5 0.85

• O.2% OFF-SE T VIELD STRENGTil.

IMPACT PROPERTIES:

ROOM TEMPERATURE 212 DEGREES F TEST IMPACT PROPERTY LONGITifolNAL TRAtJSVERSE L ot&GITUDINAL TRANSVERSE 1

E tJE RGY ABSORPTION. rT.-LBS.

12 6

20 8

BRITTLE FRACIURE %

95 95 90-95 95 2

FNERGY ARSORPTION. FT.-185.

13 8

20 10 URIIILE FRACTURE. %

95 95 90-95 95 RFFER TO rini1RES 2A-2C rOR Tl4E TEST PostTInNS At3D ORIFNIATIONS.

}k

TARLE 2.

INLAND STEEI METAIIURGICAL LADORATORY MEIALLURGICAL TEST DAIA ON FARLEY UNIT NO. 2 ANCHOR HEA0 HV 038 CIIEMICAL ANALYSIS:

C MN P

S SI CU NI MO CR As CB V

TI AL N

02 SN SB

.45

.98

.011

.029

.22

.11

.14

.22 f.12

.014

.008

.Ot

.008

.021

.009 97 PPM

.01

.010 MICROANALYSIS:

CLE ANLINESS (J-K RATING ON APPE ARANCE )

A3-4H CARDIDE MORPHOLOGY TEMPERED MARTENSITE HARUNESS (SURFACE):

BHN 429-444 (HRC CONVERTED 45-47)

HRC ACTUAL 44.0-44.5 TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL RE00CTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION CAUGE (kSI)

(KSI)

(% IN 2")

(%)

YS/TS TRANSVERSE

.505*

202.4 8.0 ft.1 TRANSVERSE

.505 161.3 192.7 8.0 13.4 0.84 LONGIIUDINAL

.504 170.4 196.7 15.0 44.9 0.87 LONGITUDINAL

.503 176.6 199.8 13.0 45.6 0.88

• O.2% orr-SET YIELD STRENGTH.

+* CliART PAPER JAMMED.

IMi'ACI PROPERTIES:

TEST IMPACT PROPERTY LONGITUDINAL TRANSVERSE LONGITUDINAL TRANSVERSE 1

ENERGY ABSORPTION, FT.-LDS.

13 8

23 to BRITTLE FRACTURE, %

95 95 95 95 2

ENFRGV A050RPTION. FT.-LDS.

13 23 BRITTLE FRACTURE. %

95 90 RFFER TO FIGURES 2A-2C FOR THF TFST POSITIONS AND ORIENTATIONS.

W HA

• Mt.

TABLE 3.

INLAND STEEI StF T AL LilRGICAL L ARORAIORY MET ALLtsRGICAL IESI DATA DN FARLEY UNII NO. 2 ANCil0R IIE AD HV O27 AF TER RE T EMPERING CitEMICAL ANALYSIS:

C See P

S SI CU NI M0 CR AS CD V

TI AL N

02 SN 58 43 1.01 082

.027

.24

.it

.52

.23 t.10

.012

.008

.01

.002

.022

.006 83 PPM

.01

.002 MICR0 ANALYSIS; CLE ANI. INESS (J-K RATING ON APPE ARANCE )

A3-4H. 8 211 CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARDNE SS ( PROF I LE ):

HRC CONVERTED (ROM BHN HRC ACTUAL OUTER M10DLE INNER outer MIDDLE INNER TOP 47 45 47 43 43 44 MIDDLE 45 44 45 43 40 42 80TIOM 45 45 47 43 43 44 TENSILE PROPERTIES:

SAMPLE VIELD*

TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE (MSI)

(KSI)

(% IN 2")

(%)

VS/TS

~~

khkNSVEhSE k hb4 56h$b khbh~

h b ~

~~hIh bhh'

~~

TRANSVEREE 2

.503 156.5 183.2 9.0 14.1 0.85

• O.2% OFF-SET VIELD STRENGTH.

k IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTV TRANSVERSE i TRANSVERSE 2 TRANSVERSE 3 ENFPGV ABSORPTION. Fi.-LBS.

8 8

8 BRITTLE FRACTURE %

95-100 95-100 95-100 LAIERAL EXPANSION. IN.

.005

.008

.005 REFER TO FIGURES 2A-2C FOR Tite TEST POSITIONS AND ORIENTATIONS.

TABLE 4.

INI AND STEEL MET ALluRGICAL I ARORATORY METALLURGICAL IESI DAI A UN F ARLEY UNIT NO. 2 ANCHUR HEAD HV O28 (NOT RETEMPERED)

CllEMICAL ANALYSIS:

C HN P

S SI CU NI MO CR AS CB V

TI AL N

02

$N SB

.44 1.04.013

.027

.25

.11

.13

.24 1.13

.083

.008

.08

.002

.023

.009 159 PPM

.01

.002 MICROANALYSIS:

CL E ANL INESS (J-K RAi]NG Ota APPE ARANCE )

A 3 - 418 H311 CARBIDE MORPHOLOGY TEMPERED MARTENSITE g

HARDNESS IPROFILED:

HRC CONVERTED FROM BHN HRC ACTUAL OUTER MIDDLE INNER OUTER MIDOLE INNER TOP 48 48 48 4G 45 46 MIDOLE 48 47 47 44 44 44 80110M 48 48 48 46 46 46 TENSII.E PROPERTIES:

SAMPLE YIELD +

TE NSIL E TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE (KSI)

(KSI)

(% IN 2*)

(%)

VS/IS IRANSVERSE t

.504*

172.9 202.5 9.0 14.5 0.85 TRANSVERSE 2

.505 158.5 192.3 9.0 90.7 0.82

• O.2% OFF-SET VIELD SIRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE t TRANSVERSE 2 TRANSVERSE 3 ENERGY ARSORPilON. Fi.-L85.

5 6

7 BRITTLE FRACTURE, %

95-100 95-100 95-100 LATERAL E7 P AN5 t oti. IN.

.00t

.004

.005 RFFER TO FIGURES 2A-2C FOR Tite TEST POSITIONS AND ORIFHTATIONS.

a TACLE 5.

INtAND STEEL METAt.LURGICAL LARORATORY METALLURGICAL TEST DATA DN FARLEY tsNIT NO. 2 ANCliOR HE AD HV 039 (NOT RETEMPERED)

CitEMICAL ANALYSIS:

C MN P

St CU NI MO CR AS CB V

TI AL N

02 SN

$8 44

.99

.013

.027

.24

.11

.12

.23 1.ft

.013

.008

.01

.002

.023

.004 261 PPM

.00

.002 MICR0 ANALYSIS:

CLE ANI.INESS (J-M RATING DN APPE ARANCE )

A3-4H. 82H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARONESS (PR0 RILE):

IIRC CONVERTED FROM BHN HRC ACTUAL DUTER MIDDLE INNER DUTER MIDDLE INNER TOP 48 48 48 46 46 47 MIDOLE 48 47 47 46 44 44 BOTTOM 48 48 48 47 46 44 TENSILE PROPERTIES:

SAMPLE VIELO+

TENSILE TOTAL REDUCTION ELASTIC TEST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE (KSI)

(MSI)

(% IN 2")

(%)

VS/TS TRANSVERSE t

.505*

183.8 207.3 9.0 15.9 0.89 TRANSVERSE 2

.503 169.8 199.8 8.0 15.9 0.85

+ 0.2% OFF-SET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPERATURE IMPACT PROPERTY TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY ARSORPTION. FT.-EBS.

6 7

7 BRITTLE FRACTURE. %

95-100 95-100 95-100 LAIERAt. ERPANSION. IN.

.006

.006

.004 REFER TO FIGURES 2A-2C FOR THE TEST POSITIONS AND ORIFNTATIONS.

T TABLE 6.

INIAND SIEEI METAtLURGICAL LAn0RATORY MET At t uRGICAL IESI DABA UN FARLEY UNIT NO. 2 ArJCHOR llE AD tty 049 AF TER REIEMPERING CHEMICAL ANALYSIS:

C MN P

S SI CU NI MO CR AS CB v

TI AL N

02 SN SB 44 1.03.082

.027

.24

.tl

.13

.24 f.13

.010

.008

.Os

.002

.023

.004 86 PPM

.08

.002 MICROANALYSIS:

CLEANLINESS (J-M RATING ON APPE ARANCE )

A3-4H. 82H CARBIDE MORPHOLOGY TEMPERED MARTENSITE HARDtJESS (PROFILE):

HRC CONVERTED FROM BHN HDC ACIUAL OUTER MIDDLE INNER DUTER MIDDLE INNER TOP 47 47 47 46 44 45 MIDDLE 47 45 44 45 43 43 BOTTOM 48 48 47 44 44 45 TENSILE PROPERTIES:

SAMPLE YIELD

• TENSILE TOTAL REDUCTION ELASTIC 1[ST STRENGTH STRENGTH ELONGATION IN AREA RATIO DIRECTION GAUGE INSI)

(MSI)

(% IN 2*)

( 7.)

VS/TS T R AraSVE RS E i

.504*

174.9 195.5 7.0 9.3 0.89 1RANSVERSE 2

.504 155.9 188.0 9.0 17.4 0.83

• O.2% OFF-SET VIELD STRENGTH.

IMPACT PROPERTIES:

ROOM TEMPER 4tuRE InsPACT PROPERiv TRANSVERSE 1 TRANSVERSE 2 TRANSVERSE 3 ENERGY ARSORPIION, FT.-LBS.

7 6

7 BRIllt f FR ACitrRE. 7.95-900 95 800 95-900 LAIERAL EuPANSION. IN.

.007

.004

.004 REFER TO F If;IMPF % 24-2P FOR lite TFST POSIllf>N*. AND ORIENIATIONS.

v Appendix A.

Inland Steel Company Chemical Department Grease Analyses of February 12, 1985. Reduced copy.

[

i REPORT OF CNE41 CAL A.% A L 7 5 1 5 INLAND STEEL C04PAMT s.............e...uee......

,,,,y,,,,

..... a... 9 1988 i

,.............s.....

Grease frem *eeten Ar.caertest, !nrye, r, %,,, ;,,,,-

r>

, See-st'e; ' eta

• fur *y.

P. ' Ice I

~

l G*$355 h3 Extract:Ste'cesfbi 9

{

i HO TA1 2

l 5

Asa Cl*

I:0, NO,*!O

• A Al) ha K Ca Pg A1m C974 p p,. ppe. per.,pg$ (g)

(

pp gg,,

p,e gg3 ft' (a)

' ! !,'. r l

l t

i t

#1. V17. Tee.

t

!ano'e 1. 1/27/2!. 0.22 0.77 3.9 (0.5 (2 160 2.8 0.24 11 4 370 0.7 84 % (i l#2.Y17. Toe.

l

}

$4 ote 2.1/2*/85 0.13 0.79 3.4 (0.$ v 2 110 2.5 0.21 11 3 aln 0.7 8400'0 i

I #3. V17. tettes.

i l

Lowest soint c.f can 1.2 0.(1 13

<0.3 (2 29 7.3 0.21 !4 7 2a0 1,3 l

l 840071 e

I 84. Y17. Esttom.

l I

First create frem (e)

(e) 12 (0.5 e2 28. 6.5 0.44 27 5 210 n.9 j

tan. Jaa,G72 i #$. V17. tatt:m.

}

Ucce* cc-tien of 1.4 0.62 14

d. 5 (2 35 7.6 0.23 (J 14 113 2.!

can. E4M73 l

I Sresse fren intericr of anct.orread (f) 1.7 3$

(0.5 (2 123 48

(.cl 221 21 433 21 lhowOrease.Vfsctn.

, crust 20!*.74 0.12 1.1 2 (n.5 (2 113 13 0.53 14 12 5:a.

6.!

i i

l 5

Ceatt ruet,

I, i

.n..................

aparg, S.f. t-t e I

OV (V

, Appendix A continued.

REPORT OF CNENICAL A.% 4 L Y S ! $

INLAND STEEL CouraNY e e.. s.. ::........ s..s. e. e s... es j

y,3,,3,., g gy, i..........w......

e.ase e.- Teae i age e *sid. !neves r

r r truary 1. te!!

e

. o.s a....

0 e.ttice W t:11ueev.

W. ice

• G.!355 Cent'nued esee two...

(a) j Neutraltratfon eucter by color indicater t*tratten. Trese nutbers will not be tre sate as t*cse obtained using Ir.ryco's method (ASTM C4da. Neutralfzation Number by Potent *ocatric Titratter.) but shou'i sufff;e fcr co.parisen our:oses. Fe are not presently set us to, run TAN by A5Dt 06(4 (b) The extraction procedure is a sinole estraction verston of the pr:cedure in ASU1 Cg74. ($f ece it is a bu*k estract'en method. it would be es:ected to give hf che' *esults t?an Inryco's sarface entraction procecure. but it was the'. fit to be more acercorf ate for higP.ly centaminated sarcies.)

A weig*ed arount (areros. ICg) cf grease was shakes in a sacaratory fur.nel wtth 100 ml of near beflfnq water. Tre l

phases were allowed to separate and the betten layer drawn off for analysts. For anica aialysis, an attouet was in.

l Jacted througn a syringa ffiter (Acredfsc a192. 0.2 ticrin) into an fon chronatogra:n (Dice.e.t 20C.11 with AS 3 secarater columr). Cuantitation was dene by coetartsen of peak rettr.ts with tr.cse of equeous standards. Cation analysis was cone by flare M.

(c)*Unitsarerelattveeeskheights. The species resconstbie cculd net be identiffed. The retentton tire ir.dtcated that I

it (they) f ateracted only ve*y viefkly with the restn. Car.

benate organic acids. tetratcrata, and flucrfde tehave sim.

l 11erly.

(d) Units are relative teak hefft.ts. The species resocestble ceuld r.ct be identf fled. The roteitten tire incicated that it (trey) inte* acted strongly with tre resta. Sulfate in.

teracts less stror. gly and tr.thaiste core so.

(e) Insufficleit tstole. It acceared trat rest cf the c:9 tents of the container had been re.oved prfor to our receivir.g it.

(3atinu94....

.. s s. e.

• a.* s... e.s s. -

0 3

C.f. 199t'

AU Appendix A continued.

REPORT OF CNENICAL ASAL1515 l*,",,,"*,,,',.,e,,

liLAND STttL C o u P A.% T 9*ette 'r!" *ead!9 :PcSer*eef. Inaves fate.;n*r 1. 18

i.e s..... e.a.

l Se-a**re v tatturtv.

8. Nee e

-lG.5205 Ceetinued esee three l

(f) Insufficient sarsle Watea analysis on this sa ste may be ecot anyway stece 11091d mater was enttuntered in the in.

terior of the anchorhead during grease saralleg.

All the used grease satoles *were laden with particulate detris.

l Sar stes 1.2.2. ene 5 had flakes of stec. ssee of thert fingernati site, all friante. The presence of particulate detrf s of unkte.n cercositicn ray make tro data for extrac*.able fees difficult te interpret since tre of stributten of conta-inar.ts witt affect tne representativeness of a sace's and their c:rrestve influence.

==

Conclusions:==

The following conclusions can te drawn frem the above data, 1.

Water is getting into the ancherhead contafeer ersba'*y in a

g Itcaid fem sicae the design = auld sets to eliminate tre pot.

elbtlity of coneessattt'. Liquid sater eJy carry larte tuae.

tities of dissolveo seterials.

I

[

2.

The sa-oles are highly cantamtr.ated with particulate detris.

The distribution end sources of the detris need to be invest.

I igated. Any kir.c of particulate debris wculd seee t: to 6n.

desirable.

3. There are large differences in the gresse analyses, yet t6e samsles form three nest grcuss. too, bott:ri, ar.d anc*tr.*esi interior. givine the data increased credtbility. Sc 4 rea.

sons for these differences 24y tot a) TPe sarries say tie mistures of gresses frca diffacer.t lots. Gresse is remved dartr.g rcuttr.e ins;ecticn and replaced with tow grease.

l t) Contanirants afresey treient eay be redistrisutee I.

by water.

t' Ccettaue1.....

I j

D.T. I* P l

l l

I L.

' Appendix A continued.

. REPORT OF CutMICAL ANALYSIS INLAND STREL C04PANY e.e..in ese...

... s.n.tv n...es y,gg, g, pg,

.i..............e.

sa 's. ss. "*

! G ease from Te9 den Ancherhead. Inry:e reheta. 1. ieer Oseraties Fetatturty.

p. Nee 6-!355 Cart'aved eace 'eue.....

I c) D'ffere*t levels cf coitattnation by selfes. water, and water.ncera matgrials ray esist.

d) The greate may be deteriorating. Nigher total acid numeers and the large At and nonexistemt 42 for t.*e ancnerneed interfer sa-ele suggest this but are fa-from conc ustve.

6 d.

The most highly car.taitnoted grease 18 that from the ar.c*.:r.

}

heed f aterter, the aest critical lecetten. This sug9ests t.*.at the entnerhees itself ray be t%e seint of entry of the c:6 teatr. ants polstbly with the tencen acting as a condutt.

ter P. Nee 2 108 Ohetnger210e[

6. Penger 2 1?a R. Carr 2 101 P. Fawkins 2.!!!

C. l.2Ith 2 1C1 l

l....................,

. e4ee,

, 84'd

/

!.3 c.r. t-4tw

-2 *.:

8 8

O

'O O

Appendix B.

Inland Steel Company Chemical Department Grease Analyses of February 26, 1985. Reduced copy.

O REPORT OF CNEWICAL A.% A L Y 5 1 5 j * * * * * '

INLA30 STEEL CouPAMT

..........................u....

y I

m t.de, tyste reerwary 15. 1911 G,eise e e

fCseest*ngTec9nology.P.Noe Les No.: G 54:9 Wate-f.tetet anatysee te)

C1*

NO2*

N0 '

304" 4

A f.a K Ca Pg 1

E!S 212 2.C2 222 U.1L 3.{ 212 112 112 21.22.-

V21. laye* 2. perimeter 9 < 0. 5

<2 27 4.7 1.7 24 4 2:3 1 7..

I VII, layer 2. ce9ter 6

<0.5

<2 20 3.8 1.3 21 4 2:3 1 7.*

V21. layee 5. perimeter (a) $ e0.5 42 16 2.5 1.2 19 3 113 1 7.1

, V21. layer 5. center (a) 6 < 0. 5

<2 19 3.!

1. 8 110 4 113 1 7,-

6 jMVCla,condaitstce(a) 17 e0.5 (c) 35 14 0.2 170 11 153 6 7.1

' Mv:13. can sfce (a) 30 # 0. 5 (c) 43 10 4.03 313 22 !!3 9 7.1 Viscomorutt 2030 82 I Grease, non 4 40.5 2

70 1.0 4.03 670 2 183 3 7.

Vis:enorast 1801 A :er, ne.

(c) 40.5 (c) 5 38 1.7 11CD 4 610 8 8.*

Water frei fill e9d of V:1

!!O

<3.5 210 35 40.1 220 15 4!3 4 2.:

Cal Liculd water encountered durtag sanniteg.

LD) Units are relative peak hetgets. The spec *es res:castble could est le lesstifted.

ic).:ot seter stnante dse to laterfe ence.

(d) Pedttted version of that in 41TM 0974 See footnote it)

(en sM of entract of annufacturer's satste of 2C90 Fa is 6.4. G 5395.

Gresse from V21 was samled in 6 approsteately 3* 1ayers untti the bottes (fill ene) was rescnes.

Infrared toectra of cae and anc9er%ead grosse sareles ass:ctated with V21 and *.'17 mere a gicd matti fer t9e stectrum of a manufactarer's sa'of e of 2092 74 and s'. estar.t' ally c18 fore 9t frem t'ione of manufacturer's sa otes of 2090 P2 (old formlatten) ar.d 1G1 A-tea (ta9d:n anticerrosten coattag). Com:arison of s:ectra also indicated 19at t.*e*e is litt's or none of farmlettens 2070 72 and IG1 A9cer in te.e used grease sazoles so far analy:st.

cc:

P. Noe 2.!C4

0. fadt99er 2 104 G. *e9ter 2 104

!-(*"J:::1

,.n.....i...........

f j8estyst:

R. Riesearan N.

• t

7. f. 1-iti (t,;,-

8 i

w

r O

I s

G tV v

Ap;andix C.

Suburban Laboratories Inc., Grease Analyses of February 21, 1985.

Reduced copy.

famosana..H A les Wee SUBURBAN LABORATORIES, Inc.

...e un onivt i.useos. unos see. 'm aa t"en888 da e.g. esoss =,.ia no e**=

e. esa Peennery 21. 1945 inryte. Ine.

Cenereta Systees Dtvisten 9PJO Seuttg Narragansett avenue "c.dI'# I8"teage,111tnets 60633 Oes P. o. Hit?'t00-9 attention: Mr. tierry tiendrickaen

,g g,,

.% w tes peceive t t /14 /$$

Chleebtee atteetes Swirtdes tfitee CentSat Te t S I 04 9e D.

(ppe)

(ppel (ppel 5

(eg tott/s) 3/L #1137 Sample 4. Weentrolled 0.stton lland Surface e

Field Esd,Ifv034V21 w/ tape 4.30 0.!!)

0.002 3 21 e6.97 3/L #1538 - Samle 0, heontrolled aruund thrvade Field End Hvnnd V.'t 0.10 0.111 0.007 1.02 47.46 S/L #1539 - Sample #1, 964 theentratted 1.40 0.113 0.007 0.18 S t.)$

3/L #190 - Crease bn. V102 Top 4.40 0.075 0.012 0.19 49.49 3/L #1541 = tasated PumpsJ ast 921 Top 0.70 0.0'IS 0.007 0.17

$4.57 3/t. #4542. #990049 TenJon f.lf fee #1 1.40 0 12S 0.007 0.27

$4.l$

3/t. #144). #940070 fenden V.17 Top #2 2.90 0.150 0.002 0.10 44.13 8/L #1449. tenott V.17. Settee Cresee 2.00 0.100 0.012 1.52 48.10 free 8.,w 44 reint fj ft/1. #1$%. f 4M f? * *'.'enValf e Sett**

let c. n,... #9 1.40 0 300 0.012 50.02 3/L #1'B4. f l'to tti i.l?, Gottoe it.i...e *.

• n f 5 1.40 0.230 0.0 12 1 34 49.14 (t'.n.e ! 5.

e I

O O

1 Appendix C continued.

Incree, tae.

Feteuery 21, 196$

Pase #2 g,,,,,g,,,g,,,

Leetes Weeelvedt 2/14/05 Olorides h

h lbtea Cantent Total #19a C.

(ppe)

(ppe)

(ppe)

(at K0H/g)

Field Anetier Cne / M 3/L #1$47. Ocease weerped in Fleetle 1.40 0.250 0.0 12 1.11 60 36 3/L #1540 tayer #1, Top Edse 0.40 0.300 0.016 0.54 46 31 4

3/L #1$49 tayer it. Top Center 0 70 0.200 0.002 0 77 44.3f 3/L #1550. Laroc #3. Edse 0.70 0.200 0.016 0.27 46.95

$/L #1511. Layer f]. Center 0.70 0 100 0.020 0.44 41.46 3/L #1552. tayer #4. Ideo 2.00 0 300 0.012 0 38 45.74 S/L #155). Layer #4, Centee 0.70 0 300 0.0 12 0.$4 47.67 3/L #1554. Lavec #6. setten ts.Se 8.70 0.}25 0.016 0.70 45 17 3/L #195). Later te, bettee Center 2.00 0 325 0.012 1.42 46 5%

fnterine eneher lined 3/L #1556. Flete red / V.17 0.70 0.260

,0.0 12 Dates Testoff 2/19/04 & 2/P0/05 M

2/*0/09

?/19/69 A80ALTSf3 CERTIFISD Bf _. /

/ 4b Otreetoe (H' filh)

Oilecideo (Seet. 1.1) stethed : Astri D.112 utteetes M.rthnet i 43tM D.912 SuIf 6 les 10theil ArH4 4*7.C Watee Content (3.eet.1.2)

N ttuma t AatM 4 95 seitutrattaatten Number (Seet. 9.))

h-thal s ASTM 0 974 (HoJ4 fled) 4

}

t, eleek toler appears in the water tereP gg w ff(g[gng aseple e.e e

. ca== nm, e a

. s

• m.

ve s.a.e Pesh.se Cemet 0p. pre, e u.seyse of $mf $89889#gt C.desegne et t e etMS e e fwe es%e anneteen a an.se lses tees.eeen. p g e sney seeemst e m e te e ss e9 m

O O

Tendon Tendon Wires (170)

Tensile-

"E Conduit Concrete Concrete

4 Bearing Place

/

lc] U l f

p l

p Shim Stack g

k n( s :.,k Protective Grease Field Anchor Head 4

Grease Cover Figure 1.

Sketch showing the approximate orientation and layout of the components at the lower end of the vertical tendons.

The sketch is not to scale.

O O

Macroetch on HV 016 only (cross hatched area).

's s

Analysis.

p

/

N Surface

\\

Hardnesses

/

J i

\\

on HV 016 & HV 038,

O G O

Microsections, (Brinell & HRC)'

/

dg e

Longitudinal &/or O O.O O

\\

Transverse.

/ /g 4,.

3 O

r I

(Microstructures g

h rated on the Ol s

Er longitudinal sections)

O' l

l O

O l

\\

O O

I Slice for

\\

/

O Cross sectional

\\

b

/

Hardness Profiles f

on HV 027 HV 028,

/

HV 039 & HV 049

\\

,/

(Brinell and HRC).

- @ denotes the nine y

positions tested.

-- ' y s

Top (Button Head) Face

{b Chemical alyses.

b

/'

opo o

e

)

l Ricrosections, i

Longitudinal &/or

(

Transverse.

Bottom (Shim) Face Figure 2A.

Test locations for the macroetch, hardnesses and microsections.

Figure is not drawn to scale.

O O

p,~,

/

N

,e

\\

\\*

/

/

O O

g

/

O O

s O

O

\\

O O

g O

O sf O

O I

g

,/

O Duplicate threaded O

.505" diameter s

trcnsverse tensile O

o j

cpccimens with 2" Duplicate threaded

\\

7[), j stuge lengths.

.505" diameter Positions 1 & 2

,f longitudinal tensile s

/

N

• '/}..

' /

gauge' lengths.

maintained on HV 027, N

f

,7 specimens with 2" HV 028, HV 039 & HV 049 but not on HV 016 & HV 038.

,/

HV 016 & HV 038 only.

Top (Button Head) Face J

3(

W 2.

l l

]

Q l

%w Bottom (Shim) Face Figure 2B.

Test locations for the Tensile Specimens.

Figure is not drawn to scale.

r

O O

y

~~ ~ { ~ s gLongitudinal full size

/

\\

impact specimens on

/

s HV 016 & HV 038 only.

[

\\

Notched normal to the rolling direction and

/

outer diameter of the

/

O O

head.

g O

O

\\

O O

I '

\\

f O

O

..I.,_.

1 O

O I

k O

O l

'\\

O O

j O

0

\\

0

/

0

\\

4 Transverse full size Iimpact specimens, f

i N

/

Notched parallel to the rolling direction.

/

~

l Top (Button Head) Face d

f P,

I g

Transverse specimens l

l l

on HV 027, HV 028, HV 039 H

"s T-- H

& HV 049 taken adjacent l

to the shim face only Bottom (Shim) Face l

Figure 2C.

Test locations for the Charpy V Notch impact specimens.

Figure is not drawn to scale.

l l

l

j j

O O

i

)

I i

i 1

f l

l l.

i

)

i i

4 I

i l

1

,I l

y r

.i Ii: 3 1. h 3 Mmt'J l

i e

1 c pergtrqttgTi4;py,rgjtr!pigel'q'A'igt{rity r

__..-- A l *3 C: ^ ai Wa ti"A *L%

i l

[

Figure 3.

Buttonhead face of the two i

sections of Anchor Head HV 016 submitted for metallurgical analysis.

Arrows indicate mating fracture faces.

Note the angled nature of the non-mating faces and the spalling on the button head faces.

I Appro:<. 0.48X i

0 O

i l

i

_ ~ '

h Y

h g

4 jf

.[$

ll

\\'

k,

'j.

~.

'k q

I

}

h.N h

4 -

,. h

,,i

.H L

4

[

'q uv p i

I, h

l

~

f i

l,

1. Re P

4 C

~

. q_.

s-4 4

A B

c r Hea

/

16.

N te

.e oc a p ara ce of th fractures.

Arrows point to region shown in Figure: 14A and 14B.

The light chevror. pattern on the outer ring indicates the ring fractures originated at or adjacent to the honeyco:"b and near the shim f ace (bottom surface as shown).

Approx. 0.77X i

I

\\

l

D O

1 I

I 1

i 1

I l

i l

1 i

2 i

ms j

-E 1

-g a=

l q

.\\

'5

-E$

.n E i

l

--E i

=

l

.=-

en =

~

l Figure 5.

Second fracture face of Section #1, Anchor Head HV 016.

Note the stria-tions on the upper two-thirds of the ring fractured face.

Origin at lower inner corner of ring.

Also note the angled honeycorab fractures.

Approx. 0.82X i

r l

\\\\

1

\\

i i

O Q

t l

l l

i J

l~-'~

I gM i

ps, I

p=.

pi.

,Q(.h,,,j,d.a'.,

w 3.g.....

. ry

.ii

.. bC b

!'i,.1 0

g,

'n -

)

. p A!/[. b h

. i.

5

[',

on:Jt

7, g.. n.

a:-

\\

i e

x p

r

(

}

'..!sjy$;f::i}.Qlh[ L '-

A.. p, f-l j

$~ #

s 'ly '

.,.s.-

5

~

e '

• 'h n w...; r,... -

• n.. :

• • c re.,

p.; i. '.

.; i,

t z

g

.e a

I

{.\\

fp ; ^;

-;,.7

'g.{'

'b '

D.,N::'G !:.,N h o '

• '. y

~."

~~

f

,, %,

• b ?

l

~ y ?;

b

.;., YS.?$f t' 'J. N l k

~'

s

< g..

=

H:

,._i Figure 6.

Second fracture face of Section #2, Anchor Head HV 016.

Note the frac-i ture appeared to originate at multiple origins in the lower half of the honey-corb.

Note the light striations and angled honeycomb fractures.

Approx. 0.78x I

O O

i l

I l

4 i

j 1r i

l',

I 0

'f' I

-~.vh 9G

~:

-.:r&h_

w Figure 7.

Photograph o f the inboard end (shim face) of HV 038.

':o te the crack between Sec-tions d2 and d3.

The split shim spacing is denoted by the arrows.

Section el (lower half) was retained by Battelle along with a small fragment from the honeycomb area.

Sections s2 and 43 (upper half) were retained by Inland.

l Approx. 0.36X

O o

l I

s3 a

i; I

I jii ;

< -r - m

4).

I,.

% N.hkj'{lp ?

?

'?,:'f,: L f. '

?

,l

?,

%M$ '

._1 $ b l

Y l

a YE.

...A=Y-kY$Abh Y ry

=.

Figure 8.

Light fractograph of Sections #2 and #3 of HV 038 retained by Inland.

The inboard (shim face) end of the head is the bottom surface, as shcwn.

The small honeycomb fragment retained by Battelle came from the circled area denoted by the "X".

Refer to Figures 3 and 4 for detailed fractographs of Sections d3 and #2, respectively.

Approx. 0.46X i

1 O

O~

l I

l

\\

L t' d j

si.2 5

t I

, m.c w&..;..

r.,

gfft.-.

1

> ;g r.

q-1 t

-r

.. yh 1. i y

-(

i w=_ #.'.

-( I.f I-j

.- j

]

Lj. ' i. j g l l, ',f } =, 't i .,* l L'O

• e h

!..? l y.. ', s e-.... ' 5, \\ ', } CT l i. i i d $dh.11 L'.' :. y ? i _al % r.m. g \\

.g; y

,w - -

f .? m =; l l i 'I d ti 3 ^' 1 Figure 3. Light fractograph of Section e3 and a portion of Section #2, Anchor Head HV 038. Note the woody appearance of the fracture. The fracture of the outer ring appears to have propagated frem the location denoted by the arrow. However, it is suspect that the head fracture origin was located within the honeycomb area, which exhibited multi-directional and possibly multi-origin fracture f aces. The small fragment re t,ained by Battelle was above and to the right of the arrow. { Approx. 0.82X l 1 'i

O O l f ( l ( i-4 n.c a. = ?. .} Y-l$,.!?$5)?.x.k:f ? b \\> { l ' "@ j.) [

1 4

u i ) ~,.,., ' - s,q,'.. ;*,.

T,., 0.. g i.

{, Qj!, = { 5.' I.J'ah j.'( '3 I, Q,( 1 j .d 1 ly- ': ?q M 3

., !.kl

.. '.. ?p, _' *. d l1, ;, j. l - IN' ,'y ' ]. r 4., ;y. ,,bt ; e,.[',' .. :..J. ;'g.?.; ;/. f _ :: s: 1 y, .g 4 ..nni -n 't l$,'. 4; ) d r , j;g!',',4p'? (cil'.f.- r ,j j l' df.I.'h!.klj]f ."k;kihf j .( j i l l o j ff!2MFifASWil E 1 i W'47, '.'.h fr. E [j ..f. f;Q.b yI .!l.Qg = r,1 T,4 e 0 P-f i b' h c-Q t. .LM ) 1 Figure 10. Light fractograph of the remainder i of Section 42, Anchor Head HV 0 38. 'l Note the woody appearance of the fracture. The fracture of the outer ring appears to have propagated from the location denoted by the arrows. However, it is suspect that the head fracture originated within thc honey-i cctb. I j Approx. 0.32X \\ J 1 e __.___._,.-,__,__._m

a l O O 4 i 1 l l l q I + i l ~ g T^E5h?'"DS'.d1 l -J e - -' Yi>C. -.... T' .w M ?i k, j ~ hl)hThpdN34lp<.yhY@f*a ?, / I k h $I' i 1 sp i to -+ Q[.)

m. gpv9mL.4 n.au Q :;QY h[:',

,5$'f!hkIh I SJ Y'ihQ:C$, f';.'.i.%VN n tjp..chy

.g$th:;(* -

f [. ' f~ fl 'y.'.' ., 7 ~_ _ l t V., -..".'..? 0 .1 . y, \\ n. t f... ,9 .thg.)}g__,,'..a,. ~ r b.. ' 9,, '..y, g..- '. - p t, ... - 9. 4 '(, j #)j [A.M. : 5. Tigure 11. Light fractograph of the mating fracture f aces of Anchor Head HV 038 between Sections 42 and d3. Note the woody appearance of the fracture and the striations on the upper half of the ring face. The fracture appears to have propagated from the location denoted by the arrows. A ppro:.:. 0.73X l 2

l l O' O^ 1 Y J l i } ^ f. e A 'k l f l t i l I \\ . f. 3 l f% g . l f.1,#i! T

t. f J

r,' l' {t -'j ~ (gj jFf] j ~

k;hIk j bfi

) xO' ) d -! il, o e'

e 1 4 i ? d N) lp.

i, t 1 t w i 4 Figure 12. Light fractograph of the fracture face of Anchor Head HV 0 39, which was separated mechanically. The arrow indicates the precracked web where it appears a fracture o r ig inated. Note the Smoother, more crystalline appearance of the pre-cracked area versus the balance of the fracture surfaces. Approx. 1.3X j' i

i w

a-st-m--mee--wW-wrgew e e er ar+v eee-----e wv Cwie-v-, e g-.umpw g.--w

i O O I r l f p l l a p l I I i l I h. '? k - e.t.g W.- '.,, - / ' y p, . so 4/ A %y y/

a, '.

• v py.... >,;

\\ 4 p x. ,. u,/ y ' < - }. % + ' . - -Q. l y. . ' :,r.. -~ 'N S# g/' '., ~ ,.. A l t i l $2 f r n._ p.v 9 m;3 ~ R i 4 ' 10p [,a.. p r, 5 s,,[ - N 'A ' ~,,. v - I / .A l >. c r,.. .; _s *f -:g" la,--.'fl ;: j 9 jf,

• ~ ~ ~

-a, a.. ), }' ~> \\ -. u /. sm-Figure 13A. Photograph of the interior surface of the galvanized grease cover from V-21 (HV 038) a f ter removal o f the grease. Note the " etched" condition o f the galvanized coating. l Approx. 0.20X 2 4 k 4 4 Y 7-=v'h----w-yarmw"m v--ww-rw-e- -e-r-m.-ma-wr--- m-we-w-r-w-- n

Q l i I ? ~ SCMK w q. __ h-pgp :h, g. ' ~ ~ #f k."k' - f s-g3

~

fj . h. t " l' : 5 y ci - 3 y;e: ' - $W?;h..s.....yl.y((.yf-[d,,])-) '. 1 M'-) ,y -: NI c . ~. -... . a..

M % **

9it; RAW i 1s n r ;g a ' ?l-lip-*Y ,.-d!yhbm k$ h:, -l ' 1 (, e. n. a+ =:,.g.,

ap -

l t. l i Figure 133. Photograph of the interior surface of the galvanized l grease cover from V-21 (HV 038) i af ter removal of the grease. Note the surface irregularities (dro s s) o f the galvanized coating. Approx. 0.50X

1 0 i.'?fM1:.l'.Ys ~ ky ~$ 5 kl h i M# $ h 5 4..y ~ ; M I.M~6, ~ -- ,I W M+ t" -S / 3- ~/ -.:.b; &.. A c. 4.? % s n.:. M. 4** 's wgei;;.m$ra ..*;...... c.: n y e. . :'* ~. 'u ~., il l, z s,2.* h y yhk'? Q.: h;":. \\

• k ~{,'

Y k,S ...?.;,%rI.-[R$. e??7 ? N.9.. M '*R *': ~ R.'Qh; ' 4l_. g j. 1.'.'t. b-I , fr '. } d.Y, 1 no W 'k f"9Aik:; hg,.d,b). 7.J:.r\\l..'.11:*'i.5h*.f ?TYly.t.ca..)},W.1 * .) w- '~ s r.h.a:r-4... 5.,:...,T..\\:. Q h .bii g.. '..' [b N .NC N. 5- % n$... C 4 # Ws. ? (V,,J K g U k* n[.i.a it. % <I. 2._h kd N $TA [6'- ' ' ' ' t a. 2WD'hjg':'i.m'! c.7:.?...'. A.! b uS.p.c - ?!. 4.%.... ..'.9, : W. 7.~. Q %'?.# p : M,' ' '~ 'Q~W .s ~, r: C .tj w o 'A. s. r::. m q:ggg s, ,,, s 3 s t,,,,,, c , 5 3,,,,. 300X 3,010X Figure 14A. SEM fractograch of HV 016 of region denoted by arrcw in Figure 4A. The low magnification shcws the inclus ion troughs. The high magnification shows the intergranular seoaration. l

Ci O 4 ':c!::l.U.. s N w r ..g,n,K. M<. 4. p:. h.b.:" 7. A V: san g,4'I$ .En

n,.,:;,.,.,..*. %..-

> qW. '"c ....*',t. .\\y s 1 2 ~ ~ - 4.[:.-:...%.[s. %.Q.. il *,1.:.i,,%.. ,:n } y, %.O. O M.xd3 k_,* [2 9.g M L 4 9' ?iM. ic:%, v, r"< ' v3 ,1 n.a'.y, Ces. :.... ' 4 s.1 :, y.

ca r

9 Q c' .4.* ;- .d '.' 'h. y, .-Y[".i.?.'N,I2 J .N('2,4 3 >. A. 9. fjd < ti.,'.;4 ],,.,:g

.,. 6; *.~ ~

wA -,., d k=.;.(..e... , -.,*.;.vs !.a d.?..*a,/ . v., w. ss - -,,s%:+c,y b:1 . p.:.. :-., w 5:. c .~-yc. 1 w;..x,g.,;7..e..,.-, s. 9%,gf..y16 ~ . q .Lg 4 b . T..- c.4W n ; 2) am1a.~,~,~ >h. < ";a .4 o., gg-y. .. -;.,b I* w;.Y l[-(. g, M 'Mi - A. IY -:.p:?~,w,h.yf,,hlk" i ~b ~ e .? 1 N,,, } 131X 951X Figure 14B. SEM fractograph of HV 016 of region denoted by arrow in Figure 4B. The low magnification shows the inclusion troughs. The high magnification shows the intergranular separation. l l I l i I

O O 4 + l .y M4 gl i { k.-. r f f).' i t a l t' i i l L 1 200X 1,000X Figure 15A. SF.M fractograph of HV 038 of the selected region denoted by the arrcw in Figures 8 and 9 (outer ring near the junction of Sections 42 and 43 and approximately 1" above the shim face). The lower magnification (left side) shows scattered inclusion troughs. The higher magnification (right side shewing the area in the box on the left side) clearly shcws hear / IGS. Note the relative cleanliness (lack of corrosion products) of the frac-ture face. 1

O O i i l 4 .i I i i i (I.'i$f i G i 't N b t ?N5b h.E. s - --mus l ( [ wN 1 ~'.p Iif I T.4 + -ll; ,i l' 200X 1,000X Figure 133. SEM fractograph of HV 038 of the selected region denoted by the arrows in Figure 10. The lower magnification (lef t side) shcws scattered inclusion troughs., '"h e higner magnl:1 cation (right side showing the area in the bo:< on the left side) clearly shows heavy l ICS. Note the relative cleanliness of the fracture face. l l l l i

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~u y-m*s g,g - If' t: 1 II l '] n* ' ' * ~ ' _,.,. Ve. m, -l$ w-g Y ~. p a

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,1:l p. ~.V ,I c ?, o 2 '~~ .-s .. w N 200X 1,000X Ficure 16A. SEM fractograph of the precrccked web of Anchor Head HV 039, Figure 12, approximately 3/4" f rom the bottom surface. The lower magnification (left side) shows the general IGS condition. The higher magnification (right side shcwing the area in the box on the lef t side) clearly shows heavy IGS. "o te the relative cleanli-ness of the fracture face. i . m. ,c

N 'I W

• M %:y e %.S u re g a.*v W,ie, y.3,*

l a g,p m+. g v.. t', p ,9g$ W ~: R :',Q[."'.?,7,,/4a 2, * ~ (' n~< 1 JAf QD., s"M l L ?. s <r. . g. i +,yp: +." Eg?ise,ce.^ s,p"?!,N['t. J A C % T f.%y > I J og/4'Y$b'$?hl,$j. g 4 w 3,.~W s.

• We l

b.~ 'I';)hE3he P -I$ ..ti ) y$_ y ?.IE' hh?hkh :), &, U/ $$$$izimSz $iEililii nf M...._ 200X 1,000X Figure 163. SEM fractograph o f the cracked web of Anchor Head HV 039, Figure 12, approximately 1-1/4" from the bottom surface. The lower magnification (left side) shows scattered inclusion troughs. The higher magnification (right side shewing the area in the box on the lef t side) clearly shows the cleavage and ductile fracture medes. 1

O O. INLAPC STEEL COMPANY OPERATING TECMGOLOGY DEPARTMENT I IPStYC0 POST TENSIONING DIVISION JOSEPH M. FARLEY DRJCLEAR PLANT, UNIT NO. 2 ANCHOR HEAD INVESTIGATION METALLURGICAL LABORATORY INVESTIGATION NO. 19975 - FINAL REPORT SY 0.E.SUDINGER ASSOCIATE METALLURGIST OPERATING METALLURGY DIVISION OPERATING TEQ4dOLOGY DEPARTMENT 9 APPROVED: P.P.NDE SUPV. METALLURGIST OPERATING METALLURGY DIV. OPERATING TECMdOLOGY APPROVED: [ G.W.HENGER / ASS!$ TANT SUPERINTENDENT OPERATING METALLURGY DIV. OPERATING TEQedOLOGY = e ,m _,-w- -.,_,.y-

P b J INRYC0 POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE I TASLE OF CONTENTS PAGE NO. I NTRODUCTI ON............................ 1 TESTING PROCEDURES...................... 4 TEST RESULTS...... VISUAL EXAMINATION.... S SEM FRACTOGRAPHY...... 9 MECHANICAL PROPERTIES. 13 CHEMICAL ANALYSES..... 13 MICR0 ANALYSES......... 15 GREASE ANALYSES....... 15 CONCLUSIONS............................. 17 REC 00SIENDATIONS......................... 19 RE F E R EPCE S.............................. 20

O o. P INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 1 ........................................p............................... INTRODUCTION THE dOSEPH M. FARLEY DAJCLEAR PLANT, UNIT NO. 2-DOLTON. ALABAMA, OPERATED gy asamansa POWER COMPANY (APCO), ENCOLMTERED THE FIELD FAILURE OF TWO FIELD ANCHOR HEADS, NV 016 AND HV 038. THE ANCWR HEADS ARE PART OF T>E POST TENSIONING SYSTEM USED IN THE REACTOR CONTAINMENT BUILDING. ANCHOR HEADS MV 018 AND HV 038 WERE LOCATED AT THE LOWER POSITION OF VERTICAL TENDONS V-17 AND V-21 RESPECTIVELY. BOTH HEADS HAD BEEN STRESSED FOR APPROXIMATELY SEVEN TO EIGHT YEARS (STRESSED ON NOVE95ER. 1975, T>stOUGH DUNE, 1977). THE ANCHORAGES WERE LAST INSPECTED IN JUNE-DULY, 1983 AT WHICH TIME THE INSPECTED ANCHORAGES (21) APPEARED TO BE INTACT BASED ON THE VISUAL INSPECTION PROCEDURES IN USE AT THAT TIME. THREE ANCHDRAGES FROM THE HV HEAT GROUP, BUT NEITHER OF THE FAILED HEADS, WERE INSPECTED IN 1983. ANCHOR HEAD HV 016 WAS DISCOVERED JANUARY 25, 1985, DURING A 30-DAY REFUELING SHUTDOWN OF UNIT NO. 2. THE RING PORTION OF THE HEAD HAD FRACTURED INTO FIVE SECTIONS AND THE HONEYCOMB PORTION HAD SHATTERED INTO APPROXIMATELY SO PIECES. TWO MAJOR FRACTURE SEC-TIONS OF THE ANCHOR HEAD HV 018, LARELED #1 AND #2, WERE RECEIVED AT THE INLAND METALLURGICAL LABORATORY ON JANUARY 29, 1985 FOR FAILURE ANALYSES. THE OTHER MAJOR FRACTURE SECTIONS OF ANCHOR HEAD HV 010 WERE SENT TO BATTELLE FOR SIMILAR FAILURE ANALYSES. INSPEC-TION OF THE OTHER ANCHOR HEADS IN THE CONTAINMENT WAS CONCURRENTLY BEING PERFORMED. IN ADDITION, FIVE GREASE SAMPLES FROM THE LOWER END OF TENDON V-17 WERE SUBMITTED TO THE INLAND METALLURGICAL LABORATORY FOR CHEMICAL ANALYSES. ON JAPA1ARY 30, 1985 DURING THE INSPECTION OF UNIT NO. 2. FRACTURED ANCMR HEAD HV 038 WAS DISCOVERED. THE HEAD HAD FRACTURED INTO T>ctEE SECTIONS PLUS ONE SMALL FRAGMENT FROM THE HONEYCOMB AREA. THE ENTIRE ANCHDR HEAD WAS RECEIVED AT THE INLAND METALLURGICAL LABORATORY ON FEBRUARY 18, 1985, AND WAS dOINTLY INSPECTED (VISUALLY, USING A LOW POWER N!CROSCOPE AND SCANNING ELECTRON MICROSCOPE, SEM, ON THE $NALL FRAGMENT) BY INLAND METALLURGICAL LA80RATORY PER50pedEL, G. ScretIDT OF BECHTEL REPRESENTING THE APCO. T. GROENEVELD OF BATTELLE AND H. PRES $ WALLA 0F INRYCO ON FESF.UARY 18, 1985. AFTER THE EXAMINATION AND A

O O P A INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 2 ........................................s............................... e [ JOINT AGREEMENT, SECTION #1, REPRESENTING APPROXIMATELY 50% OF THE ANCHOR HEAD, AND THE SMALL DONEYCOMB FRA434ENT WERE RETAINED BY t BATTELLE FOR THEIR ANALYSES OF THE FAILURE. SECTIONS #2 AND #3 WERE RETAINED BY INLAND FOR FAILURE ANALYSES. AT THIS TIME, ALL de j ANCHOR HEU25 OF THE HV HEAT IDENTIFICATION WERE BEING REMOVED FROM THE CONTAIDs4ENT BUILDING. PRIOR TO RECEIVING ANCHOR HEAD HV 038 THE GREASE COVER FROM THE LOWER END OF VERTICAL TENDON V-21 WAS SUBMITTED TO THE INLAND METALLURGICAL LABORATORY ON FEBRUARY 9, 198S. THE GREASE COVER CONTAINED THE GREASE RETAINED UPON REMOVAL FROM THE TENDON. ALSO SUBMITTED WERE TWO UNCONTROLLED GREASE SAMPLES TAKEN FROM ANCHOR HEAD HV 038 AFTER IPCOVERING AND PRIOR TO DETENSIDNING THE HEAD. SAMPLING AND ANALYSES OF THE GREASE AND A METALLURGICAL EVALUATION OF THE GALVANI2ED GREASE COVER WERE REQUESTED. FOUR ANCHOR HEADS, NV O27, HV O28, HV 039 ANO HV 049 WHICH WERE DETENSIONED AND REMOVED PROM THE CONTAIMIENT BUILDING, WERE RECEIVED BY THE INLAND METALLURGICAL LABORATORY ON FEBRUARY 20, 1985 FOR MOD! PIED (ABBREVIATED) TESTING. THESE ANCHOR HEADS WERE MAGNETIC PARTICLE INSPECTED AFTER DETENSIONING AM ANCHOR HEAD HV 039 WAS FOUND TO BE CRACKED (REFERRED TO AS PRECRACKED) ON THE SHIM FACE IN THE CENTER OF THE HONEYCOMB WEBS. THE REMAINING THREE HEADS WERE NOT PRECRACKED. ANCHDR HEADS HV O27 AND HV 049 WERE THEN SENT TO FPM HEAT TREATING - ELK OROVE VILLAGE, ILLINDIS, AND WERE RETEMPERED AT E50 DEGREES F FOR FOUR HOUR $. THE FOUR ANCHOR HEADS WERE THEN LOAD TESTED AT THE UNIVER$17Y OF ILLINOIS, CHAMPAIGN-URBANA, ILLINDIS, BY INRYCO. AFTER LOAD TESTING, THE ANCHOR HEADS WERE AGAIN MAGNETIC PARTICLE TESTED WITH CRACKS BEING NOTED ON ANCHOR HEADS HV O27 AND HV 048 (REFERRED TO AS POST-CRACKS) AND ANCWR HEAD HV 039 FURTHER CRACKED (PRECRACKED AM POST-CRACMED) IN THE CENTER OF THE HONEYCOMB WERS ON THE SHIM FACE. THE LOAD TEST CONSISTS OF $1MULATING THE ACTUAL LOADING CONDITIONS OF THE ANCHOR HEADS (LDADED TO 120-150% GUTS, I.E., THE MINIMUM GUARANTEED ULTIMATE TENSILE STRENGTH OF THE TENDON) AS CLOSELY AS POSSIBLE USING A 3,000,000 LB. UNIVERSAL TESTING MACHINE. ALL FOUR HEADS WERE LOAD TESTED SATISFACTORILY; THAT IS, NO RADIAL ! FLEXURAL) FRACTURES OR PREMATURE PUNCHOUT (SHEAR) FAILURES OF THE >WNEYCOMB OCCURRED.

. _ = - _ o o, P A INRYC0 POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 3 THE FIELD ANCHOR HEADS ARE 4" THICK BY 9.375" DIAMETER CYLINDRICAL PARTS AND ARE SUBJECTED TO A COMBINATION OF SHEAR, COM-PRESSIVE AND TENSILE LDADS IN SERVICE. FIGURE 1 IS A SKETCH OF THE APPROXIMATE LAYOUT OF THE SYSTEN COMPONENTS AT THE LOWER END OF THE VERTICAL TENDONS. ONE MJNDRED SEVENTY (170) 0.2S7" DIAMETER HOLES ARE DRILLED LONGITUDINALLY THROUGH THE CENTRAL DONEY'll0MB AREA 0F THE ANCHDR HEAD. THE STEEL WIRES OF THE TEMONS FIT THROUGH THE HDLES AND ARE COLD HIADED. AFTER INSTALLATION IN THE STRUCTURE. 1 THE ANCHOR HEADS ARE THEN JACKED AWAY FROM THE BEARING PLATE TO STRESS (TENSIONI THE TENDONS. SPLIT SHIM PLATES ARE THEN INSERTED SETWEEN THE AMCHOR HEAD AND THE BEARING PLATE TO MAINTAIN THE TENS-ILE STRESS. AFTER TENSIDNING, GALVANIZED GREASE COVERS ARE PLACED OVER THE HEADS AM A HEATED CORROSION PROTECTION GREASE (VISCO O 2000P WAX-SASED PETROLEUM paACLEAR CASING FILLER PACKING GREASE) IS THEN PUMPED INTO THE SYSTEM FROM THE LOWER EDW OF THE TENDON AND CIRCULATED UNTIL A CONSTANT TEMPERATURE IS ACHIEVED. THE GREASE COMPLETELY ENCASES THE ANCHORAGES AND TENDONS. PEROIDICALLY, THE GREASE IS " TOPPED-OFF" FROM THE UPPER END OF THE TENDON. THERE ARE 3S7 TEND 0!!S IN THE CONTAIPelENT STRUCTURE OF WHICH 130 ARE VERTICAL, 134 ARE HOOP AND 93 ARE DOME. l THE ANCHOR HEADS ARE MACHINED FROM 10" DIANETER HOT WORKED AND l AMEALED ASTM A-322 GRADE 4140 OR 4142 ALLOY STEEL ROUNDS. THE HV I ANCHOR HEADS WERE PRODUCED FRON STEEL PURCHASED BY WESTERN CONCRETE FROM E. M. JORGENSON, WHO PURCHASED IT FROM REPUBLIC STEEL COMPANY, HEAT #8081524. THE HEAT WAS MADE IN 1973. THE ANCHOR HEADS WERE HEAT TREATED BY DOWNEY STEEL TREATING - DOWNEY, CALIFORNIA. TO MILITARY SPEC. MIL-H5875 TO A MARONESS OF MtC 40-44. HEAT TREATING i CHARTS OR TEMPERATURE RECORDS WERE NOT REQUIRED AT THE TIME THE HEADS WERE MANUFACTURED. THIS REPORT COVERS THE FAILURE ANALYSES OF ANCHOR HEADS HV 018 AND HV 038 AND THE METALLURGICAL EVALUATION OF THESE ANCHORAGES ALONG WITH ANCHORAGES HV 027 HV 028, NV 039 AND HV 049. ALSO INCLUDED ARE THE CHEMICAL EVALUATIONS OF CREASE SAMPLES DETAINED FROM THE LOWER EMS OF THE VERTICAL TENDONS V-17 AND V-21 (ANCHORAGES HV 018 AND HV 038 RESPECTIVELY1 THE GALVANIZED OREASE COVER PROM V-21 (MV 038) WAS ALSO EXANINED. IN ADDITION, INFORMATION ON THE ON-SITE Cope!TIONS AND PHOTOGRAPHS OF THE ON-SITE CONDITIONS WERE CONSIDERED. l 4 j I l

-- =.__ O O INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 4 TESTING PROCEDURES THE BASIC METALLURGICAL TESTING PROCEDURES FOR THE TESTING OF THE SUBMITTED FIELD ANCHOR HEAD SAMPLES WERE AS FOLLOWS: 1. VISUAL EXAMINATION WAS DONE IN THE AS-RECEIVED CO WITION OF BOTH ANCHOR HEADS Ape GREASE SAMPLES. ' SAMPLES OF THE GREASE RETAINED ON ~ ANCHOR HEADS HV 016 AND HV 038 WERE OBTAINED. THE GREASE SAMPLING FROM THE GREASE COVER FROM TENDON V-21 ANO VISUAL EXAMINATION OF THE GREASE SAMPLES WILL BE COVERED IN THE GREASE ANALYSES SECTION OF THIS REPORT. 2. SAMPLES WHID4 REQUIRED OPGREASING WERE THEN CLEANED WITH $7000 ART'S SOLVENT OR ALOtDPCL A M FURTHER EXAMININED WITH BOTH THE UNAIDED EYE AND LOW POWER MICROSCDPE. PHOTOGRAPHS WERE OBTAINED OF ANCHOR HEADS HV 016 AND HV 038 APC THE FRACTURE FACES OF THE CRACKS ON HV 039. THE GREASE COVER FROM TENDON Y-21 WAS ALSO PHOTOGRAPHED. i 3. SCAfedING ELECTRON M?llROSCOPE (SEM) FRACTOGRAPHY WAS PERFORMED ON ALL OF THE FRACTURE FACES LOCATED ON THE ANCNOR HEADS AFTER THE HEADS WERE SECTIONED TO A SUITABLE SIZE. IN ADDITION. ALL OF THE TRANSVERSE TENSILE TEST FRACTURE FACES Afe SELECTED CHARPY V NOTCH IMPACT SPECIMEN FRACTURE FACES WERE EXAMINED. ALL OF THE ABOVE FRACTURES WFRE EXAMINED FOR FRACTURE MOCES 1.E., DUCTILE, BRITTLE i (CLEAVAGE), SfEAR OR INTERGRAfRJLAR SEPARATION (IGS). ANY OTHER FEATURES OF INTEREST WERE NOTED. 4 COMPLETE CHEMICAL ANALYSES INCLUDING RESIDUAL ELEMENTS WERE OBTAINED FROM THE ANCHOR HEADS. 5. NECHANICAL PROPERTIES INCLUDED THE FOLLOWING: 1 A.) BRINELL AND ROCKWELL OGIC) HARDNESS WERE OBTAINED ON THE RING SURFACE OF ANCHOR HEADS MV 018 AND HV 038 Ape ON THE RING CROSS-SECTION OF ANCMDR HEADS HV 027, MV 028 HV 039 AND HV 049. a B.) TENSILE PROPERTIES WERE OBTAINED FROM THE RING AREA 0F EACH I ANCHDR HEAD USING STApSARD.505" DIAMETER ROUND TENSILE SPEC-IMENS WITH 2* GAUGE LENSTHS. ANCHOR HEADS HV 018 Ape HV 038 WERE TESTED IN THE LONSITUDINAL Ape TRANSVERSE DIRECTIONS AND THE BALANCE OF THE ANCHOR HEADS WERE TESTED IN THE TRANSVERSE DIRECTION ONLY.

O O P A i i l l l a INRYC0 POST TENSION!NG DIVISION - INVESTIGATION NO. 19975 PAGE S ........................................y............................... 1 THE FOLLOWING PROPERTIES WERE DETAINED:

1. ) YIELD STRENGTH. KSI (0.2% OFF SET) 2.) ULTIMATE TENS!LE STRENGTH. KS!

3.) TOTAL ELONGATION, % IN 2" GAUGE LENGTH 4.) REDUCTION OF AREA. % IN ALL CASES. INO!VIDUAL TEST RESULTS WERE REPORTED WITH NO AVERAGING SE!NG 00NE. C.) CHARPY Y NOTCH IMPACT PROPERTIES USING FULL $22E IMPACT SPEC-IMENS WERE DETAINED FROM THE RING AREA. ANCHOR HEADS HV 016 ANO HV 038 WERE TESTED IN THE LONGITUDINAL AND TRANSVERSE DIRECTIONS AT ROOM TEMPERATURE AM3 212 DEGREES F. THE BALANCE OF THE ANCHOR HEADS WERE TESTED AT ROOM TEMPERATURE IN THE TRANSVERSE DIRECTION ONLY. THE FOLLOWING PROPERTIES WERE OBTAINED: 1.) ENERGY ASSORPTION, FT.-LES. 2.) BRITTLE FRACTURE. %

3. ) LATERAL EXPANSION, INCHES (HV 027,HV 028.HV 039.HV 049)

IN ALL CASES, INDIVIDUAL TEST RESULTS WERE REPORTED WITH NO AVERAGING BEING DONE. IN MOST CASES, DUPLICATE OR TRIPLICATE TESTS WERE OSTAINED. 6. METALLOGRAPHIC EXAMINATION TO EVALUATE THE MICROSTRUCTURE (AN EVALUATION OF THE HEAT TREATMENT) ANO MICROCLEANLINESS AS RATED ON LONGITUDINAL MICROSPECIMENS WERE OSTAINED FROM THE RING AREAS USING THE @ K RATING SYSTEM SY APPEARANCE ONLY. IN ADDITION, SELECTIVE MICROSECTIONS FROM THE HONEYCOMB AREAS WERE ALSO EXAMINED. THE LOCATIONS OF THE BASIC TESTING OF THE ANCHOR HEADS ARE SHOWN l IN FIGURES 2A-C. AS WELL AS COULD BE MAINTAINED ON THE SUSMITTED SAMPLES. IT SHOULD BE NOTED THAT. IN SOME INSTANCES, THE TESTING WAS LIMITED DUE TO THE SAMPLE SUSMITTED. 4 THE GREASE COVER FROM THE LOWER END OF VERTICAL TENDON V-21 WAS EXAMINED VISUALLY AS RECEIVED AM3 AFTER GREASE SAMPLING. THE COVER WAS THEN SECTIONED IN ORDER TO OSTAIN ZINC COATING WEIGHTS AND MICR0 SECTIONS FOR EVALUATION OF THE GALVANIZED COATING INTEGRITY. .m--.- m .,m_n_-..-_-

O O INRYC0 POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE B TEST RESULTS ( VISUAL EXAMINATION ANCHOR HEAD HV 01B (FIELD FAILURE) THE TWO SUBMITTED SECTIONS OF ANCHOR HEAD HV 01B ARE SHOWN IN FIGURE 3. THE MATING FRACTURED FACES OF THE HEAD EXHIBITED A WOODY, FIBROUS-TYPE FRACTURE APPEARANCE. THE FRACTURE FACES WERE NORMAL TO THE INBOARD (SHIM FACE) AND WERE STRAIGHT AM ALIW6ED PARALLEL TO THE ROLLING DIRECTION. IT IS NOT KNOWN IF THE FRACTURE COINCIDED WITH THE SPLIT SHIM SPACE. IT APPEARS THAT THE FRACTURE OF THE RING PORTIONS OF THE HEAD ORIGINATED AT OR NEAR THE SHIM FACE OF THE HEAD NEAR OR AT THE HONEYCOMB; SEE FIGURE 4. NOTE THE INDICATIONS OF A LIGHT CHEVRON PATTERN POINTING TOWARD THESE LOC-ATIONS. A DEFINITE ORIGIN OF THE WNEYCOMB FRACTURE WAS NOT APPARENT. ALTHOUGH THE FAILURE OF THE HEAD PROBABLY ORIGINATED WITHIN THE HONEYCOMB AND PROPACATED TO THE OUTER RING. NOTE THAT THE HONEYCOMB HAD REPORTEDLY SHATTERED INTO APPROXIMATELY 80 PIECES; HOWEVER. THE MONEYC006 FRACTURES IN THE AREA 0F THE MATING FACES REMAINED PARALLEL TO THE ROLLING DIRECTION APEl NDRMAL TO THE SHIM FACE INDICATING A BIAXIAL TENSILE LOADING. THE ADDITIONAL TWO FRACTURE FACES APPEAR TO BE SECONDARY FAILURES. THEY ALSO HAVE THE WOODY FRACTURE APPEARANCE, BUT THE FRACTURE FACES ARE ANGLE 0 AT APPROXIMATELY 10 DEGREES FROM THE ROLLING DIRECTION. THE FRACTURE FACE FROM SECTION #1 ALSO HAS A STRIATED APPEARANCE ON THE UPPER TWO-THIRDS OF THE FRACTURE Ifd3!CATING A PROGRES$1VE FRACTURE WHICH PROBABLY OCCURRED LAST AND ORIGINATED NEAR THE BOTTON (SHIM FACE) 0F THE HEAD. THE FRACTURE FACE OF SECTION #2 APPEARS TO HAVE ORIGINATED AT 8EILTIPLE ORIGINS (AS INDICATED BY THE RATCHET MARKS) AT, NEAR OR WITHIN THE HONEYCOMB; SEE FIGURES S AND B. THE FRACTURES IN THE HONEYCOMB AREAS ADJACENT TO THE SEC0fd3ARY FRACTURES WERE ANGLEO TO THE ROLLED DIRECTION INDICATING A MORE COMPLEX. POSSIBLY TENSILE-SHEAR LOAD-ING. IT WAS ALSO NOTED THAT SPALLING OF THE EUTT0petEAD SURFACES OF THE HEAD HAD OCCURRED ADJACENT TO THE SECONDARY FRACTURES INDICAT-ING SIGNIFICANT COMPRESSIVE LOADING ALONG THAT SURFACE; SEE FIGURE 3. I i i l l l

O O A INRYCO POST TENSIONING DIVISION = INVESTIGATION NO. 19975 PAGE 7 ........................................~................................ ANCPOR HEAD HV 038 (FIELD FAILURE) THE SHIM FACE OF ANDOR HEAD HV 038 IS SHOWN IN FIGURE 7. WHEN THE ANOCR DEAD WAS RECEIVED, SECTION #3 WAS PCT COMPLETELY SEPARATED FROM SECTION #2. THERE WAS ALSO A SMALL FRAS4ENT OF THE SONEYCONS PROM THE AREA CIRCLED IN FIEJRE 8. THE FRAGMENT WAS iJOINTLY EXAMINED AfC RETAINED BY BATTELLE. A LIGHT FRACTOGRAPH OF THE RADIAL FRACTURE OF SECTIONS #2 AND #3 IS SHOWN IN FIGURE 5. THE FRACTURE FACES AS SHOWN IN FIGURE 8 ALSO HAD A WOODY, FIBROUS APPEARANCE, WERE PENIMAL TO THE SHIM FACE AND WERE STRAIGHT AND ALIWdED PARALLEL TO THE ROLLING DIRECTIONS EXCEPT IN THE AREA WHERE THE FRACTURE FACES OF SECTIONS #1,

1. 2 AND #3 INTERSECTED.

THE FRACTURES WERE NOT ALIGNED WITH THE SPLIT SHIM SPACE. WHICH IS DENOTED BY THE ARROWS IN FIEJRE 7. A DEFINITE FAILURE POINT ORIGIN IS NOT READILY APPARENT IN FIGURE 8 OR THE DETAIL FIGURES 9 AND 10. I HOWEVER, THE FRACTURES OF THE OUTER RING AREAS APPEAR TO HAVE l ORIGINATED AT OR ADJACENT TO THE HONEYCOME AND IN THE LOWER QUARTER l OF THE RING. IPCEED. THE FAILURE OF THE HEAD MAY HAVE ORIGINATED WITHIN THE PONEYCDem AREA APC PROPAGATED TO THE OUTER RING. l SECTION #3 WAS SEPARATED FROM SECTION #2 AND APPEARS TO BE A SECONDARY FAILURE. AGAIN. THE FRACTURED FACES EXHIBITED THE WOODY FRACTURE APPEARANCE, SUT THE FACES ARE ANGLED AT APPROXIMATELY 10 DEGREES FROM THE ROLLING OIRECTION. THE FRACTURED FACES ALSO.HAVE l A STRIATED APPEARANCE ON THE UPPER HALF OF THE FRACTURE, SIMILAR TO l THE SECONDARY FRACTURES OF ANOCR HEAD HV Ots. IT APPEARS THAT j THIS FRACTURE ALSO ORIGINATED AT OR ADJACENT TO THE HONEYCOMS AND SHIM FACE; SEE FIGURE 11. l ANCHOR HEADS HV O27. HV O28, HV 039 HV 049 (DETENSIONED ANCHOR HEADS WHICH HAD NOT FAILED) l ANCHOR HEAD HV O28 HAD NO CRACKS. THE OTHER THREE ANCHORAGES REVEALED CRACKS ALONG THE CENTRAL HONEYCOMB WEBS ON THE INSOARD (SHIM) FACE. >WNEYCDee SECTIONS WERE CUT OUT OF THE THREE ANCHORAGES CONTAINING THE CRACKS AND THEN SEPARATED TO REVEAL THE

O O P INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 5 FRACTURE FACES. CARE WAS TAKEN IN SECTIONING HV 038 TO INCLUDE BOTH PRECRACKS AND POST-CRACKS. THE FRACTURED FACES OF THE THREE ANC>ORAGES ALSO SHOWED THE WOODY. FIREROUS APPEARANCE. FIGURE 12 SHOWS THE FRACTURE FACE OF HV 039; THE ARROW INDICATES THE PRE-CRACKEL WEB AREA WHICH HAD A $800THER, 80RE CRYSTALLINE APPEARANCE AS COMPARED TO TIE ADJACENT POST-CRACKED WEB AREAS. GENERAL C0004ENTS ON VISUAL EXAMINATION THE ANCHORAGES SHOWED VARYING DEGREES OF CORROSION PITTING OF THE TENDON HOLES. HV 018 AND HV 038 APPEARED TO SHOW A HIGHER DEGREE OF PITTING THAN THE OTHER FOUR ANCHORAGEt, 'ThE CORROSION PITTING INO! CATES THE ACTIVE CCDRCSION HAD OR WAS OCCURRING WITHIN THE TENOON HOLES. THE GALVANIZED GREASE COVER FROM THE LOWER END OF VERTICAL TENDON V-21 (HV 038) EXHIBITED AN

• ETCHED" CONDITION ON THE INNER SURFACES AS SHOWN IN FIGURE 13A.

THE

• ETCHED
• CONDITION IS AN INDICATION THAT ACTIVE CORROSION HAD OCCURRED OR WAS DCOURRING WITHIN THE GREASE COVER. THE GREASE COVER FROM THE LOWER END OF TENDON V-17 (HV 016) HAD A $1MILAR
• ETCHED" APPEARANCE BASED ON ON-SITE PHOTOGRAPHS. SURFACE IRREGULARITIES. WHICH APPEARED TO BE DROSS. WERE ALSO EVIDENT ON THE IpedER SURFACES OF THE GALVANIZED COVER; SEE FIGURE 138.

WHEN OSTAINING GREASE SAMPLES FROM THE TENDON V-21 GREASE COVER. POCKETS OF LIOUID WATER WERE ENCOUNTERED WITH APPROXIMATELY 200 NL OF WATER BEING FOUND NEAR THE LOWER END OF THE COVER. THIS AMOUNT OF WATER IS EXCESSIVE. l PHOTOGRAPHS OF ANCHOR HEAD HV 038 SEFORE DETENSIONING SHOWED WATER BEADS BEING VISIBLE ON BOTH THE SHIM PLATES AND THE ANCHOR HEAD ITSELF. l 1 f

P 4 i INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE S .........................................L.............................. i

• SCAMING ELECTRON MICROSCOPY (SEM)

FIGURES 4-5 AND 9-12 HAVE ACCOMPANYING OVERLAYS. THE OVERLAYS SHDW BOTH THE POSITIONS AT WHICH SEE ANALYSES WERE OBTAINED, I.E., THE CROSS-MATCHED AREAS, Ate THE POSITIONS AT WHICH INTERGRANULAR SEPARATION (IGS) WAS NOTED, I.E., THE RED HI9tLI9ffED AREAS. THE OVERLAY METHOD WAS USED IN ORDER TO CLEARLY PRESENT THE SEM ANALYSES OF THE HEAD FRACTURES AND ALSO ALLOW AN UNOBSTRUCTED VIEW OF THE FRACTOGRAPHS. IN ALL OF THE SECTIONS PERTAINING TO THE SEM FRACTOGRAPHY, THE TOP SURFACE OF THE ANCHOR HEAD REFERS TO THE BUTT 0fetEAD SURFACE AfC THE BOTTOM SURFACE OF THE ANCHOR HEAD REFERS TO THE SHIM SURFACE. ANCHOR HEAD HV 018 (FIELD FAILURE) SCANNING ELECTRON MICROSCOPIC (SEM) ANALYSES WERE PERFORMED ON ALL THE RING FRACTURE FACES AND SELECTED AREAF OF THE HONEYCOMB; REFER TO FIGURES 4-5. THE RING OF THE HEAD AND HONEYCOMB REVEALED INTERGRANULAR SEPARATION (IGS) TO VARYING DEGREES; SEE FIGURES 14A AND 148. IGS INDICATES THAT THE FRACTURE OCCURRED WHILE THE HEAD WAS IN A PARTIALLY EMBRITTLED COPCITION. THE MATING FRACTURE FACE, SHOWN IN FIGURES 4A AND 45, REVEALED IOS AT THE TOP AND BOTTON, INNER SIDE ( ADJACENT TO THE DONEYCOMB) OF THE RING. THE BALANCE OF THE SECTIONS EXAMINED FROM THESE FRACTURES PREDOMINANTLY SHOWED COMBINATIONS OF CL$ AVAGE AND DUCTILE FRACTURE MODES. 1 4-l EXAMINATION OF THE SECONDARY FRACTURE FACES REVEALED THE I FOLLOWING: SECTION

1. 1, SHOWN IN FIGURE B,

EXHIBITED HEAVY IGS ACROSS THE BOTTCH 'HIRD OF THE RING: SECTION #2, SHDWN IN FIGURE B, T SHOWED HEAVY IGS AT TFT4 BOTTOM HALF IPetER SIDE OF THE RING. THE HONEYCOMB AREA REVEALED IGS ON BOTH THE VERTICAL AND ANGLED WEB FRACTURES. ALSO, THE SPALLED AREAS OF THE TOP (BUTTONHEAD) END OF THE RING, SHOWN IN FIGURE 3 EXHIBITED HEAVY IGS. . -... -,,. ~,,,.. _. - r _.,,,._y... .e

I O O INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 10 ,. ANCHOR HEAD HV 038 (FIELD FAILURE) SEM ANALYSES WERE PERFORMED ON THE FRACTURED FACES OF ANCDE)R HEAD HV 038; SEE FIGURES 9-11. AGAIN. THE RING AND HONEYCOMB SHOWED IQS; SEE FIGURES ISA AND 158. THE RING PORTION OF SECTION

1. 2 (RIGHT SIDE OF FIGURE 8 AND FIGURE 10) SHOWED A NARROW BAfC OF IGS ADJACENT TO THE M3NEYCOM AT THE BOTTOM THIRD OF THE RING.

APPROXIMATELY SO% OF THE RING PORTION CF SECTION #3 (LEFT SIDE OF FIGURE 8 AND FIGURE S) S W WED INTERGRApelLAR SEPARATION. THE MAIN LCCATION OF THE INTERGRAf43LAR SEPARATION WAS ON THE IpedER SIDE (ADJACENT TO THE MllNEYCOMB) OF THE RING. ONLY A SMALL AMOUffr OF INTERGRANULAR SEPARATION WAS SEEN AT THE BOTTOM OF THE RING. THE NON-RADIAL FRACTURE FACE BETWEEN SECTIONS #2 AND #3; SEE FIGURE 11. SHOWED IGS ACROSS THE LOWER THIRD OF THE RING. THE FRAGMENT OF THE HONEYCOMB. WHICH WAS RETAINED BY BATTELLE. WAC EXAMINED AND SHOWED HEAVY IGS ON BOTH SIDES OF THE FRAGMENT. ANCHOR HEAD HV 038 (DETENSIONED ANCHOR HEAD WHICH HAD NOT FAILED) THE ANALYSIS WAS PERFORMED ON THE HONEYCOMB FRACTURED FACES OF AN:: HOR HEAD HV 039. THE PRECRACKED WER. SHOWN IN FIGURE 12 i EXHIBITED HEAVY IGS ALONG THE BOTTOM INCH OF THE WEB; SEE FIGURE 1BA. ABOVE THE BOTTOM INCH THE FRACTURE DEIDE WAS A COMBINATION OF CLEAVAGE ANO DUCTILE SEE FIGURE 188. THE OTHER WEBS WHICH WERE CRACKED OURING LOAD TESTING $> OWED A COISINATION OF CLEAVAGE AND OUCTILE FRACTURE MODES. NO IGS WAS NOTED ON THESE POST-CRACKS. i i

4 O O P A INRYCO POST TENSIDNING DIVISION - INVESTIGATION NO. 18975 PAGE 11 . ANCM3R HEAD HV O27. HV 049 (DETENSIONED ANCHDR HEADS WHICH HAD NOT FAILED) THE FRACTURED WEBS WHICH WERE POST-CRACKED DURING LDAD TESTING EXHIBITED A COMBINATION OF CLEAVAGE AND DUCTILE FRACTURE MDDES: NO IGS WAS PRESENT. BOTH OF THESE HEADS HAD BEEN RETEMPERED AT 850 DEGREES F FOR FOUR M3URS AND THE POST-CRACKING REPORTEDLY OCCURRED AT 115% GUTS.

GENERAL COMMENT

S ON THE SEM FRACTOGRAPHY ~ THE PREDOMINANCE OF THE IGS WITHIN AND TOWARDS THE HONEYCOMB AREA AND THE TOP AM BOTTOM RING SURFACES IS AN INDICATION OF AN EXTERNAL EMBRITTLING AGENT RATHER THAN A TEMPER EMBRITTLEMENT PHENOMENON. TEMPER EMBRITTLEMENT SHOULD RESULT IN A MORE UNIFORMLY DISPERSED IGS WHICH SHOULD BE MORE EVIDENT IN THE MORE SLOWLY COOLED AREAS OF THE HEAD, I.E., THE CENTER PORTION OF THE OUTER RING. IN ADDITION, SEM ANALYSES WERE PERFORMED ON THE TRANSVERSE TENSILE TESTS OF ALL THE ANCHOR HEADS AND SELECTED TRANSVERSE IMPACT TESTS. NO IGS WAS NOTED ON ANf OF THESE TEST SPECIMENS. THE LACK OF IGS ON THE TEST SPECIMENS !$ ALSO AN INDICATION THAT THE EMBRITTLEMENT IS NOT TEMPER EMBRITTLEMENT AND THE EMBRITTLING AGENT IS NO LONGER PRESENT. 1 BASED ON THE

• FRESH" APPEARANCE OF THE FRACTURE FACES. NO EVIDENCE OF OUENCH CRACKING WAS OSSERVED. QUENCH CRACKS WOULD HAVE AN OXIDIZED SURFACE DUE TO THE PRESENCE OF TEMPER SCALE.

l 1 l l ~

l l P A O O INRYCO POST TENSIONING O! VISION - INVESTIGATION NO. 19875 PAGE 12 THE FRACTURE FACES ALSO APPEARED TO BE FREE OF CORROSION PRO-OUCTS. THE LACK OF CORROSION PRODUCTS IS AN IMICATION THAT THE FRACTURES ARE PROSASLY NOT STRESS CORROSION CRACKING. ENERGY DIS- } PERSIVE OUALITATIVE SEN X-RAY ANALYSES OF THE FRACTURE FACES SHDWED NO IDENTIFIABLE CORROSION PRODUCTS OR EMBRITTLING SPECIES. HOWEVER. IT SMULD SE fGTED THAT THE X-RAY LNd!T IS MT CAPASLE OF OETECTING EITHER HYDROGEN OR CARBON. THE WOOOY FISROUS NATURE OF THE FRACTURES WAS CAUSED BY THE i PREFERENTIAL ALIGletENT OF THE NONMETALLIC INCLUSIONS IN THE ROLLING DIRECTION. THE INCLUSIONS CREATE FLOW LINES WHICH ACT AS PLANES OF WEAKNESS. THIS CONDITION WOULD RESULT IN LOWER TRANSVERSE FRACTURE RESISTANCE OF THE HEADS. \\ 1 m,,

O O 1 INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 13 , t'ECHANICAL PROPERTIES THE MECHANICAL PROPERTIES OF THE ANCDOR HEADS ARE PRESENTED IN THE ATTACHED TABLES 1-5. BOTH BRINELL M G ROCKWELL MARONESS TESTS WERE CONOUCTED ON THE ANCPOR HEADS. HARDNESS TESTS WERE PERFORMED ON THE TRANSVERSE RING SURFACE OF ANCHDRAGES HV 018 AM HV OSS, AND CROSS-SECTIONAL HARDNESS PROFILES WERE OSTAINED ON ANCHORAGES HV s 027 HV 028 HV 039 AND HV 049. THE ROCKWELL VALUES WERE ON THE AVERAGE 2 TO 3 POINTS LOWER THAN THE CONVERTED BRINELL VALUES. THE SPECIFIED HARDNESS RANGE WAS >5tC 40-44 THE TENSILE PROPERTIES WERE OSTAINED WITH MACHINED.505" DIA-METER SPECIMENS WITH 2" GAUGE LENGTHS FROM THE RING AREA 0F THE HEADS. THE STRENGTH LEVELS ARE HIGHER AND THE DUCTILITIES ARE WITHIN THE RANGE OF DATA THAT WAS POUND ON PREVIOUSLY TESTED FIELD ANCHOR HEADS PRODUCED FROM ALLRf!NUM GRAIN REFINED AISI 4140 OR 4142 ALLOY STEELS. THE HIGHER STRENGTH WOULD MAKE THE MATERIAL MORE SUSCEPTIBLE TO STRESS CORRDSION CRACKING OR HYDROGEN STRESS CRACK-ING. THE EFFECT OF THE MARDENARILITY OF AISI 4140 OR 4142 ALLOY STEEL ON THE TENSILE PROPERTIES IS SHOWN IN TABLES 3-6. TEST 1 FROM HEADS HV 027 HV 028 HV 039 AND HV 049 WAS OSTAINED IMMEDIATELY ADJACENT TO THE SHIM FACE. TEST 2 WAS APPROXIMATELY 1-1/2" ABOVE THE SHIM FACE. IN ALL CASES. TEST 2 SHOWED LOWER STRENGTH LEVELS. HOWEVER, ONLY THE RETEMPERED HEADS HV 027 AND HV 049 SHOWED GREATER DUCTILITY ON TEST 2 AS COMPARED TO TEST 1. HEADS HV 028 AND HV 039 WHICH WERE NOT RETEMPERED, SHOWED COMPARABLE OR LESS DUCTILITY ON TEST 2. THE IMPACT PROPERTIES WERE OBTAINED WITH FULL $1ZE CHARPY V NOTCH SPECIMENS, ALSO FROM THE RING AREA OF THE HEADS. THE IMPACT ENERGIES ARE NORMAL FOR THE ALLOY STEEL PRODUCT IN THE QUENCHED AND TEMPERED CONDITION. THE ANCHDRAGES WHICH WERE RETEMPERED AT 450 DEGREES F FOR FOUR HOURS DID NOT SHOW SIGNIFICANT DIFFERENCES AS COMPARED TO THE OTHER ANCHORAGES. THIS INDICATES THAT THE ANCHORAGES WERE PROSABLY HEAT TREATED AS SPECIFIED.

O O A INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 14

• CHEMISTRY THE CHEMICAL CHECK ANALYSES OF THE ANCHOR HEADS OSTAINED FROM THE OUTER RING ARE GIVEN IN THE ATTACHED TABLES 1-6.

THE LADLI CHEMISTRY OF REPUBLIC HEAT #8061524 AND THE CHEMICAL REQUIREMENTS OF ASTM A-322 GRADE AISI 4140 OR 4142 HDT ROLLED ALLOY STEEL SARS ARE GIVEN BELOW: DESCRIPTICN C toi P S SI NO CR LADLE, HEAT 6061524 .44 .98 .015 -.030 .23 .22 1.07 ASTM A-322* GRADE 4140 .38/ .75/ .035 .040 .20/ .15/ .80/ OR 4142 .45 1.00 .35 .25 1.00 eSINGLE NUMBERS ARE MAXIMUMS. THE ASTM SPECIFICATION IS IDENTICAL TO INRYCO SPECIFICATION 1849 DATED iJULY 15, 1972, WITH THE EXCEP-TION OF THE CARBON RANGE OF.40/.45% ON THE INRYCO SPECIFICATION. THE CHEMICAL ANALYSES OF THE HEADS ARE IN LINE WITH THE ASTM SPECIFICATION AND IN GOOD AGREEMENT WITH REPUBLIC'S HEAT. IN ADDITION, CU. NI. AL, N, 02, AS, TI, CB. V. SN AND 58 CHECKS WERE AT A SATISFAC-TORY RESIDUAL LEVEL. THE RESIDUAL ELEMENTS INDICATED A PROBABLE ELECTRIC FURNACE STEELMAKING ORIGIN. COATING WEIGHTS OF THE GALVANIZED CDATING OF THE GREASE COVER FROM THE LOWER END OF TENDON V-21 (HV 0353 WERE 3.3 02./SQ.FT. ON THE INNER SURFACE AND 2.9 02./SQ.FT. ON THE OUTER SURFACE. WITHOUT KNOWLEDGE OF THE ORIGINAL COATING WEIGHTS, THE SIGNIFICANCE OF THESE C0ATING WEIGHTS CAN NOT BE DETERMINED. THE COATINGS ARE HEAVY, HOT DIPPED GALVANIZED COATINGS WHICH WOULD OFFER SATISFACTORY ATMOSPHERIC CORROSION RESISTANCE.

O O INRYCO POST TENSIONING DIVISION. INVESTIGATION NO. 19975 PAGE 15 ........................................r.............................. MICROANALYSES LONGITUDINAL A M TRANSVERSE MICROSECTIONS WERE OSTAINED FROM BOTH THE RING AND MNEYCOMB AREAS OF ANCHORAGES HV 016 AND HV 034. IN ALL CASES, THE SECTIONS INTERSECTED FRACTURE FACES. THE FRACTURES APPEARED TD BE A CDMBINATION OF BRITTLE, INTERGRANULAR OR DUCTILE FRACTURES. NO EVIDENCE OF PRIOR CRACKING WAS APPARENT. LONGITUDINAL MICROSECTIONS FROM THE RING AND HONEYCOMB AREAS OF ANCHORAGES HV 027 HV 028, HV C39 AND HV 049 WERE SECURED. THE HONEY-COMS SECTIONS OF ANCHORAGES HV 027. HV 039 AND HV 049 INTERSECTED THE FRACTURE FACES CAUSED BY LOAD TESTING. THE FRACTURES APPEARED TO BE DUCTILE. THE MICROCLEANLINESS OF THE HEADS WAS RATED A3-4H AND B2-3H ON THE AVERAGE, PER THE J-K RATING SYSTEM, AM RATED ON APPEARANCE ONLY. THE MICROSTRUCTURE OF THE HEADS WAS TEMPERED MARTENSITE. INDICATING A QUENCHED AND TEMPERED CONDITION. LIGHT REMNANTS OF BANDING WERE EVIDENT. THE TENDON HOLES SHOWED A LIGHT PARTIAL SURFACE DECARBURIZATION (<.001" DEEP). NO CLUSTERED SULFIDES WERE EVIDENT. PRIOR AUSTENITIC GRAIN SIZE WAS 5 OR FINER. THERE WERE NO CHROMIUM CARRIDES EVIDENT. THERE WAS NO EVIDENCE OF CARBON RESTORATION. MICROSECTIONS WERE OBTAINED FROM THE GALVANIZED GREASE COVER OF V-21. NO DETECTABLE CORROSION ATTACK WAS EVIDENT ON THE GALVANIZED COATING. THE GENERAL COATING THICKNESS WAS BETWEEN.004" AND.007" THICK, BUT THICKNESS UP TO.042' WAS NOTED. ALL THE SURFACES OF THE COVER EXAMINED WERE COATED. GREASE ANALYSES ATTACHED IN APPENDICES A AND B ARE THE INLAND STEEL COMPANY CHE-MICAL DEPARTMENT ANALYSES OF VARIOUS GREASE SAMPLES DETAINED FROM THE GREASE SUPPLIER (UNUSED SAMPLES), FROM THE GREASE COVERS FROM THE LOWER END OF TENDONS V-17 AND V-21 AT VARIOUS LOCATIONS WITHIN THE COVERS, AND FROM THE SAMPLES OBTAINED FROM THE SUSMITTED ANCHORAGES HV 015 AND HV 038. THE SAMPLES FROM COVER V-17 WERE OSTAINED ON-SITE. THE SAMPLES FROM COVER V-ll1 AND ANCHORAGES HV 015 AND HV 038 WERE OBTAINED AFTER THE SAMPLES WERE SHIPPED TO THE INLAND METALLURGICAL LABORATORY. -v,--- ,,v----_,-,w . -. ~ - m a,. e

O O INRYC0 POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 18 4,............................... LIQUID WATER WAS ENCOUNTERED DURING THE SAMPLING OF ANCHDRAGES HV 016 4HD HV 03B AND COVER V-21. PARTICULATE DEBRIS AM ZINC FLAKES WERE ALSO FOUND IN THE SAMPLES FROM COVER V-17 AND ANCHORAGE HV 013. THE WATER FROM COVER V-21 HAD A PH OF B.3 AND CONTAINED 150 PPM CL, 250 PPM $04, 290 PPM NA, 15 PPM K AND 480 PPM CA. THERE CAN BE ND DOUBT THAT THE POST TENSIONING SYSTEM OF THE FARLEY UNIT NO. 2 IS Cop (TAMINATED WITH WATER. I NOTE THAT INLAND USED A DIFFERENT EXTRACTION METHOD FOR THE WATER f EXTRACTABLE IDN ANALYSIS OF THE GREASE. INLAND USED A BULK EXTRACTION METHOD AND INYRCO'S PROCEDURE SPECIFIES A SURFACE EXTRACTION METHOD WHICH COUL') NOT BE RUN ON A TIMELY BASIS AT INLAND THE BULK METHOD, WHICH WOULD BE EXPECTED TO RESULT IN HI#tER LEVELS OF IONS, MAY BE MORE REPRESENTATIVE OF THE RESPECTIVE GREASE SAMPLE. APPENDIX C. ATTACHED, IS A COPY OF THE GREASE ANALYSES OF VARIOUS GREASE SAMPLES AS OBTAINED BY SUBURBAN LABORATORIES. INC., OF HILLSIDE, ILLINOIS. SAMPLES WERE SENT TO SUBURBAN WHEN IT WAS DETERMINED THAT INLAND COULD NOT CONFORM TO INYRCO'S SPECIFIED TEST METHODS FOR THE GREASE ANALYSES ON A TIMELY BASIS. INLAND RECEIVED AND FDRWARDED TO SUBURBAN SAMPLES S/L 1537-1541 WITHOUT ANY ANALYSES BEING DONE AT INLAND. SAMPLES S/L 1842-1546 WERE ANALYZED BY INLAND AND ARE COVERED IN INLAND REPORT DATED 2/12/85. INLAND SAMPLED, BUT DID NOT ANALYZE, SAMPLES 5/L 1547-1555 FROM COVER V-21. INLAND RETAINED AND ANALYZED LAYERS #2 AND #5 FROM COVER V-21, WHICH ARE COVERED IN INLAND REPORT DATED 02/23/B5 ALONG WITH SAMPLE 5/L 1558 (HV 038 ). IN ADDITION. A WATER SAMPLE OBTAINED FROM COVER V-21 WAS SENT TO SUBURBAN FOR ANALYSES. HOWEVER, IS NOT INCLUDED IN THE ATTACHED REPORT. COMMENTS ON THE ANALYSES COVERED IN THE ATTACHED SUBURBAN REPORT SHOULD BE SOLICITED FROM SUBURBAN LABORATORIES, INC. 4

O O i INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 17 i CONCLUSIONS 2 FOLLOWING ARE THE CONCLUSIONS BASED ON THE FAILURE ANALYSES OF ANCHDR HEADS HV 018 Ape HV 038 Ape THE ETALLURGICAL EVALUATION OF THESE ANCHDRAGES ALONG WITH ANC>ORAGES HV 627, NV 028, MV 039 Ape HV 049. THE j CONCLUSIONS ARE ALSO SASED ON OSSERVATIONS Ape CHEMICAL EVALUATIONS OF GREASE SAMPLES OSTAINED PROM GREASE COVERS FROM THE BOTTOM END OF TENDONS V-17 AND V-21 WHICH COVERED ANCHORAGES MV 018 AND HV 038 RESPECTIVELY. ALSO EXAMINED WAS THE GALVANIZED GREASE COVER FRON V-21 (HV 038). IN ADDITION. INFORMATION ON THE ON-SITE CONDITIONS AND PHOTOGRAPHS OF THE ON-SITE CopeITIONS WERE CONSIDERED. 1. THE FAILURE OF ANCHORAGES HV Ott AND HV 034 WAS DUE TO THE IN-SERVICE PARTIAL EMBRITTLEMENT OF THE ANCHORAGES As INDICATED SY THE PRESENCE OF SIGNIFICANT AMOUNTS OF INTERGRANULAR SEPA-RATION (IGS) ON THE FRACTURE FACES. WE HAVE CONCLUDED THAT THE EMBRITTLING SPECIES IS HYDROGEN. WHICH RESULTS IN HYDROGEN STRESS CRACKING (H5C). THE IGS WAS NOST PRONOUNCED IN THE ANCHORAGE CENTRAL DONEYCOMS AREA AND EXPOSED AREAS OF THE ANCHORAGE SEARING Afe SUTTOPMEAD FACES. 2. THE MAJOR SOURCE OF THE HYDROGEN WAS THE PRESENCE OF WATER IN CONTACT OR #DJACENT TO THE ANCHOR HEADS WITHIN THE GREASE COVERS. ATOMIC OR NACENT HYOROGEN WAS GENERATED SY THE COR-ROSION REACTIONS OF IRON Ape ZINC IN THE PRESENCE OF WATER. SAMPLES OF GREASE FROM SOTH V-17 AND V-21 WERE CONTAMINATED WITH WATER. THE FAILURES WOULD NOT HAVE OCCURRED WITHOUT THE PRESENCE OF THE WATER. 1 3. THE WATER PRESENT IN THE GREASE COVERS IS HEAVILY CONTAMINATED WITH CATIONS AND ANIONS. WE CONCLUDE THIS WATER IS PRESENT SECAUSE OF ENVIR0f0fENTAL C0peITIONS. .i 4 THE TENDON HOLES OF THE ANCHORAGES SHDwED VARYING DEGREES OF ), CORROSION PITTING INDICATING THAT ACTIVE GENERAL CORROSION WAS OCCURRING WITHIN THE ANCHORAGES. 1 5. THE IfmER SURFACES OF THE GREASE COVER. WHICH ARE ZINC COATED AL50 SHOWED AN

• ETCHED" CON 0! TION Ipe!CATING ACTIVE CORROSION AND ZINC-RICH PARTICLES WERE FOUND IN THE GREASE SAMPLES FROM V-17, i

) i

= O O A INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE IS ....................................... 4............................... S. ANCHOR HEAD NV OSS, WHICH WAS DETENSIONED, MAGNETIC PARTICLE INSPECTED. LOAD TESTED AT THE UNIVERSITY OF ILLINDIS AND RE-MAGNETIC PARTICLE INSPECTED WAS FOUND TO BE CRACKED ON DETENSIONING AM FURTHER CRACKED ON LOAD TESTING. THE CRAOCS ON DETENSIONING WERE PREDOMINANTLY IGS, WHILE THE CRACKS ON LOAD TESTING WERE A COMINATION OF CLEAVAGE AM DUCTILE TRACTURE MDOES. THIS INDIC.TES THAT THE EMBRIT-TLING SPECIES WAS PRESENT DURING THE FORMATION OF THE IN-SERVICE CRACKS AM WAS NDT DURING THE FORMATION OF THE LOAD TESTING CRACKS. ANCMDRAGE HV 039 HAD INITIATED AN IN-SERVICE FAILURE AND. IN TIME, WOULD HAVE FAILED. 7. OTHER POSSIBLE SOURCES OF THE IGS HAVE BEEN ELIMINATED BY THE COMBINATION OF SCApedING ELECTR'A MICROSCOPY (SEM) AND MECHANICAL TESTING OF THE ANCHORA4ES. NONE OF THE LABORATORY-CREATED FRACTURES (TENSILE SPECI4 ENS AND IMPACT SPECIMENS) SHOWED ANY IGS. THE IN-SERVICE /RACTURES WERE RELATIVELY CLEAN AND SHOWED M EVIDENCE OF OXIDE OR IDENTIFIABLE COR-ROSION PRODUCTS. ADDITIONAL CONCLUSIONS THE SUSMITTED ANCHORAGES HAD HARDNESSES WHICH WERE WITHIN THE SPECIFICATION. THE SUBMITTED ANCHORAGES HAD STRENGTH LEVELS WHICH WERE HIGHER SUT DUCTILITIES WHICH WERE WITHIN THE RANGE OF DATA THAT WAS FCUND ON PREVIOUSLY TESTED ALUMINUM GRAIN REFINED FIELD ANCHOR HEADS. THE HIGHER STRENGTH LEVELS WOULD RESULT IN A GREATER SUSCEPTIBILITY TO HSC AND IGS. THESE HID4ER STRENGTH LEVELS ALONE WOULD NOT HAVE RESULTED IN THE SUEJECT FAILURES. THE ANCHOR HEAD SAMPLES MET THE CHEMICAL REQUIREMENTS OF THE ASTM AND INRYCO SPECIFICATIONS AND ALL RESIDUAL ELEMENTS WERE AT ACCEPTABLE LEVELS. THE MICR0 STRUCTURES AND MICR0 CLEANLINESS OF THE SUBMITTED SAMPLES l WERE AS EXPECTED FOR THE STEEL GRADE AfC CONDIT10N. i THE RETEMPERED ANCHORAGES INDICATED THAT THE HEADS WERE HEAT TREATED AS SPECIFIED. j .r. -.y,y, m..-.-... ~, m -.m .%m- -,_,._.,_,.r. e..

O O INRYC0 POST TENSIONI;4G DIVISION - INVESTIGATION NO.19175 PAGE IS REC 00esENDATIONS 4 1. ELIMINATION OF WATER IN THE POST TENSIONING SYSTEM 15 ESSENTIAL FOR THE ELIMINATION OF THE RECURRENCE OF SIMILAR FAILURES. THE ANDUNT OF WATER THAT CAN BE TOLERATED CAN M T BE OETERIIINED WITH ANY CERTAINTY. l 2. IF THE WATER CAN NOT BE ELIMINATED, THEN THE ANCM RAGES SM ULD SE INSPECTED AT SOME INCREASED FREQUENCY TO INSURE AGAINST FAILURES AND THE COLLECTION OF EXCES$1VE AIGUNTS OF WATER WITHIN THE SYSTEN. i THE VERTICAL TEfe0NS, DUE TO THEIR ORIENTATION, S MULD BE SUSPECT AND THOROUGHLY EXAMINED FOR THE PRESENCE OF WATER. MMtEVER, THIS DOES NOT PRECLUDE INSPECTION OF THE HOOP OR DONE TEM ONS 3. BASED ON CURREfft VISUAL INSPECTION PROCEDURES, IT IS NOT POSSIBLE TO DETERMINE IF AN ANCHORAGE IS CRACKED IN THE CENTER AREA 0F THE HONEYCOMB ON THE SHIM SIDE OF T>E ANCPGRAGE. DETENSIONING AND MAGNETIC PARTICLE INSPECTION ARE NECESSARY TO DETERMINE ZF CRACKING SUCH AS TW4T NOTED ON ANCHORAGE HV 030 !$ PRESENT, i A. WE RECOne4END LOWERING THE STRENGTH LEVELS OF THE ANCHORAGES IF POSSIBLE WITHIN THE SCDPE OF THE ORIGINAL DESIWi. WHILE THIS WILL REDUCE THE SUSCEPTIBILITY OF THE ANCHORAGE TO HYDROGEN STRESS CRACKING (HSC). IT DOES NOT PRECLUDE THE OCCURRENCE OF HSC. DETERMINATION OF THE OPTIIGJN STRENGTH LEVELS IS OUTSIDE THE SCOPE OF THIS INVESTIGATION. t i 4 4 ,---n-,m--, ---r- ., -, - ~~-.--,- n. -n----,,-,----.,,._,m,-,,-- ,--~-,-,,,me,n- ,e .,-------w, .,w-e,-,-. . - - -m --w---

O O P A INRYC0 POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 20 LIST OF REFERENCES a 1. INRYCO SROCD8JRE ON POST TENSIONING SYSTEMS FOR CONTAINNENT SUILDINGS. 2. INRYCO MATERIAL SPECIFICATION 1849 DATED dJLY 15, 1972. 3. ASTN SPECIFICATION A 322-84A (1970). 4. INRYC0 QUALITY CONTROL PROCEDURE NO. SQ 7.2 SHEATHING FILLER ANALYSIS DATED NOVEMBER 18, 1983. 5. INRYC0 NATERIAL SPECIFICATION 1322-40 POST TENSIONING ANCHOR-HEAD DATED JJNE 24, 1980. S. INRYC0 NATERIAL SPECIFICATION 1001-40 GUIDE FOR PREPARATION AND CERTIFICATION OF TEST INFORMATION DATED d WE 24, 1980. 7. INRYC0 NATERIAL SPECIFICATION 1848-40 FORGING REQUIRENENTS FOR ANCHORAGES DATED JJNE 24, 1980. 8. INRYC0 NATERIAL SPECIFICATION 1E45 POST TENSIONING ANCHORAGE NATERIAL CLEANLINESS DATED eJUNE 24, 1980. J 9. PRIVATE CORRESPONDENCE, " STATISTICAL ANALYSIS OF MECHANICAL PROPERTIES OF AL GRAIN REFINED ANCHORAGES," DATED OCTOBER 17, 1980. 10. H.H.PRESSWALLA,

• INVESTIGATION FOR FEASIBILITY OF LOWER STRENGTH AM HIGHER DUCTILITY FOR INRYC0 170W ANCHORHEADS,"

DATED SEPTEMBER 22, 1980. 11. INLAND STEEL NETALLURGICAL LABORATORY INVESTIGATION NO. 08775 - FINAL REPORT DATED MAY 28, 1980. 12. PRIVATE CORRESPO WANCE WITH H.HENDRICKSON OF INRYC0 FEBRUARY 1, 1985 TO DATE.

O O P A INRYCO POST TENSIONING DIVISION - INVESTIGATION NO. 19975 PAGE 21 13. PRIVATE CORRESPONDANCE WITH H.H.PRESSWALLA 0F INRYCO FEBRUARY 1, 1985 TO DATE. 14 PRIVATE CORRESPONDENCE WITH G.SCHIMDT OF BECHTEL DATED FEBRUARY 23, 1985. 15. TRIP REPORT AM ATTACMENTS COVERING FEBRUARY 7,1985 MEETING WITH NRC DATED FEBRUARY 11, 1985. 18. TRIP REPORT AND ATTAC MENTS COVERING MARCH 1, 1985 MEETING WITH NRC DATED MARCH 4, 1985. 17. VARIOUS INLAND STEEL PRELIMINARY REPORTS SETWEEN FEBRUARY 1, 1985 TO DATE. 18. SUSURBAN LABORATORIES, INC., GREASE ANALYSIS REPORT DATED FEBRUARY 21, 1985. 19. ASM METALS HANDSOOK, STH EDITION, VOL. 10, " FAILURE ANALYSIS AND PREVENTION," 1975. 20. ASME HANDBOOK ' METALS PROPERTIES,* 1954, 21. ALLOY DIGEST FILE CODE SA18, "AISI 4140," MAY, 1954. 22. ASTM STP S45, 'FRACTOGRAPHY IN FAILURE ANALYSIS." 1977. 23. AINE CONFERENCE PROCEEDINGS,

• ADVANCED TECW IQUES FOR CHARACTERIZING HYDROGEN IN METALS," 1981.
• THE ABOVE REFERENCES ARE NOT FOOTNOTED IN THE REPORT.

I l DER:RLB ATTACHMENTS PHOTOGRAPHS l 1 .}}