Determination of transfer stress from ruptured pre-load galvanised tendons in tanks and bund walls

Circular concrete tanks and containment bunds constructed by the pre-load method involves pre-stressing the concrete by repeatedly wrapping layers of highly tensioned tendons. Each layer is covered with gunite. Corrosion may lead to rupture and an explosive type failure is avoided if the gunite is able to absorb the transfer stress. Zinc galvanizing is used to increase the tendons resistance to corrosion but its smoothness can influence bond characteristics, as can corrosion if extensive. This paper investigates the pre-stress transfer of ruptured pre-load tendons in gunite, both in the uncorroded and corroded state. Laboratory testing was conducted where tendons were pre-loaded in custom-built stressing moulds (to 1000 MPa) and simulated gunite applied. Different degrees of accelerated corrosion were applied to the tendons (0-10%). The bond stress at transfer was determined by measuring the contraction of the tendon during release of the pre-stress (replicating a broken tendon). The results show that a low bond stress was found either as a result of the smooth zinc coating (uncorroded tendons) or due to higher levels of corrosion. These results were compared to design equations from Eurocode 2 and recommendations are made for reducing the bond coefficient Ƞp1, the coefficient that takes into account the type of tendon and the bond situation. Analysis is subsequently conducted to determine the transfer stress in the gunite by modelling single and double tendon ruptures and establishing the magnitude of compressive stress which, if excessive, may lead to an explosive type failure of the gunite.