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A Thesis Entitled by Charles William Colony Submitted to the Graduate A Thesis Entitled An Evaluation of Corrosion Sensors for the Monitoring of the Main Cables of the Anthony Wayne Bridge by Charles William Colony Submitted to the Graduate Faculty as partial fulfillment of the Requirements for the Master of Science Degree in Civil Engineering Dr. Douglas Nims, Committee Chair Dr. Mark Pickett, Committee Member Dr. Joseph Lawrence, Committee Member Dr. Amanda Bryant-Friedrich, Dean College of Graduate Studies Copyright 2016 This document is copyrighted material. Under copyright law, no parts of this document may be reproduced without the expressed permission of the author ii An Abstract of An Evaluation of Corrosion Sensors for the Monitoring of the Main Cables of the Anthony Wayne Bridge by Charles William Colony Submitted to the Graduate Faculty as partial fulfillment of the Requirements for the Master of Science Degree in Civil Engineering The University of Toledo August 2016 The Anthony Wayne Bridge is a suspension bridge located in Toledo, Ohio currently undergoing an extensive rehabilitation project. Internal inspection revealed corrosion of the steel wires within the bridge’s main cable. The bridge operators have elected to pursue the installation of a dehumidification system. Such a system injects dry air into the cable to lower the relative humidity and stop the corrosion process. The research presented in this thesis investigates the use of the Analtom AN110 corrosion sensor and its applications on the Anthony Wayne Bridge. Dehumidification systems require extensive monitoring systems to ensure their effectiveness and proper operation. The AN110 corrosion sensor uses linear polarization resistance (LPR) technology to measure corrosion rates in real time. Such measurements could potentially provide data valuable in ensuring the effectiveness and progress of the drying-out process. Included is an extensive review of the bridge’s rehabilitation process, a literature review of dehumidification and the application of LPR technology, and laboratory testing of the corrosion sensor. Laboratory testing involved the exposure of the sensor to cyclic relative humidity to observe the relationship between corrosion rate and relative humidity. iii The use of the AN110 corrosion sensor in the monitoring of the future dehumidification system on the Anthony Wayne Bridge is recommended. Among other factors, testing results showed a clear and consistent relationship between the recorded corrosion rate and the relative humidity. The sensor functions as expected and confirms the existing understanding of the effect of relative humidity on the corrosion of steel. iv Acknowledgments The author would like to Dr. Doug Nims for his continual guidance and support throughout the project. The author would also like to thank Mr. Doug Rogers and Mr. Jim Bradley of ODOT for their assistance. The author gratefully acknowledges the thesis committee members for their time and effort spent reviewing the project. Lastly, the author would like to thank his parents and friends for their support, without whom this would not have been possible. v Table of Contents Abstract……………………………………………………………………………………….iii Acknowledgments…………………………………………………………………………....iv Table of Contents……………………………………………………………………………...v List of Tables………………………………………………………………………………...vii List of Figures……………………………………………………………………………….viii 1 Introduction and Background……………………………………………………………….1 1.0 Project Background Introduction ………………...……………………………….1 1.1 Bridge Description……………………………………………………………...…1 1.2 Background on Acoustic Emission………………………………………………..2 1.3 Condition of the Superstructure and Main Cables Before Rehabilitation………...3 1.4 Inspection Background……………………………………………………………5 1.5 Rehabilitation……………………………………………………………………...9 1.6 Cable Rehabilitation Plans……………………………………………………….10 1.7 Laboratory Studies On the AWB………………………………………………...12 1.8 Summary and Future Plans ……………………………………………………...14 2 Objectives and General Description of Research……………………………………….…15 2.1 Research Objectives………………………………………………………...……15 2.2 General Background of Research………………………………………………..16 3 Literature Review…………………………………………………………………………..18 3.1 Dehumidification………………………………………………………………...18 3.1.1 Dry Air System………………………………………………………...19 3.1.2 Cable Sealing System….………………………………….…………...21 vi 3.1.3 Monitoring and Control System………………………………………..22 3.1.4 Maintenance and Operation Costs………………………….………….22 3.1.5 Case Studies……………………………………………………………23 3.1.5.1 Humber Bridge…………………………………….…………23 3.1.5.2 Forth Road Bridge………………………………..…………..25 3.1.5.3 William Preston Lane, Jr. Memorial Bridge..………………..27 3.2 Linear Polarization Resistance and the AN110 Corrosion Sensor…...………….30 3.2.1 Linear Polarization Resistance Background…………..……………….30 3.2.2 Analatom AN110 Corrosion Sensor…………………..……………….31 4 Experimental Results and Discussion……………………………………………………...34 4.1 Development of the Experimenal Program………………………………………34 4.1.1 Environmental Chamber ………………………………………………34 4.1.2 Cyclic Testing………………………………………………………….38 4.2 Experimental Results and Discussion……………………………………………39 4.2.1 Test 1…………………………………………………………………...39 4.2.2 Test 2…………………………………………………………………...42 4.2.3 Test 3…………………………………………………………………...46 5 Conclusions and Recommendations……………………………………………………….51 5.1 Summary of the Anthony Wayne Bridge Cable Rehabilitation………………….51 5.2 Experimental Results…………………………………………………………….52 5.3 Recommendation of Application to Anthony Wayne Bridge……………………53 5.4 Future Research………………………………………………………………….54 References……………………………………………………………………………………57 vii List of Tables Table 1-1: Strength and Factor of Safety Summary for Brittle Wire Model…………8 Table 5-1: Estimated cost of corrosion sensors on AWB……………………………54 viii List of Figures 1-1: Anthony Wayne Bridge at the Beginning of the Rehabilitation………...………..2 1-2: Detail of Existing Fracture-Critical Trusses……………………………………...3 1-3: Existing Cable……………………………………………………………………3 1-4: Elephant’s Foot at Cable Band…………………………………………………...3 1-5A: Overview of Drain Hole at Midspan…………………………………………...4 1-5 B: Close-up of Drain Hole at Midspan……………………………………………4 1-6: Acoustic Sensor Layout…………………………………………………………..5 1-7: North and South Cable Opening Locations………………………………………6 1-8: Corrosion Stages of Cable Wires………………………………………………...7 1-9: AWB after the conclusion of the approach and superstructure rehabilitation…..10 3-1: Relationship between relative humidity and atmospheric corrosion of iron...….19 3-2: Dehumidification by sorption…………………………………………………...20 3-3: Example of an injection point, with connection to dry air flow visible………...20 3-4: The Cableguard Wrap System during installation................................................21 3-5: Humber Bridge dehumidification systemayout…………………………………25 3-6: Progress of the drying process on Forth Road Bridge…………………………..27 3-7: Potential wire breaks on the Westbound Bay Bridge…………………………...29 3-8: AN110 data acquisition unit with attached LPR sensors……………………….31 3-9: The corrosion sensor attached to environmental chamber……………………...31 3-10: Experimental results from cyclic testing of corrosion sensor within a cable….32 ix 4-1: Environmental chamber…………………………………………………………35 4-2: Temperature versus time in environmental chamber when using Peltier cell…..36 4-3: Temperature versus time in environmental chamber when using heating bulb...37 4-4: Preliminary test results observed in real-time…………………………………..37 4-5: Test 1, Corrosion rate and relative humidity over 24-Hour period……………..39 4-6: Test 1, corrosion rate and humidity during first cycle of humid air…………….40 4-7: Test 1, second cycle of humid air……………………………...………………..41 4-8: Test 2, Corrosion rate and relative humidity over 24-Hour period……………..42 4-9: Test 2, corrosion rate and humidity during first cycle of humid air…………….43 4-10: Test 2, second cycle of humid air……………………………………………..44 4-11: Test 1, Corrosion rate and relative humidity over 24-Hour period……………46 4-12: Test 1, corrosion rate and humidity during first cycle of humid air…………...47 4-13: Test 1, second cycle of humid air……………………………………………...48 4-14: Relationship between relative humidity and corrosion………………………..50 x Chapter 1 1.0 Project Background Introduction The Anthony Wayne Bridge (AWB) is a suspension bridge spanning the Maumee River in Toledo, Ohio. Located on Ohio State Route 2, the bridge is owned and operated by the City of Toledo. The Ohio Department of Transportation (ODOT) has inspection and major maintenance responsibility. The bridge is undergoing a rehabilitation that aims to extend the life of the bridge an additional 50 to 75 years. ODOT is managing the rehabilitation. The rehabilitation began in 2014 and will continue through at least 2018. The rehabilitation of the main suspension cable incorporated the state-of-the-art use of acoustic emission (AE) sensors throughout the examination of the cables. The AE sensors provided valuable data on the existing state of the bridge’s cables by monitoring potential internal wire breaks. Under the scope of this project, several laboratory studies utilized AE and corrosion sensors to further develop an understanding of the corrosion process. Future plans for the rehabilitation include a planned dehumidification system. This dehumidification system is designed to limit future corrosion within the main cables. 1.1 Bridge Description Construction on the AWB (Figure 1-1) was completed in 1931 and it is currently the only suspension bridge in the ODOT inventory. The bridge is 4 lanes wide with a 60 foot wide deck. The main cable-supported span is 785 feet with
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