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"Corten" redirects here. For the commune in Moldova, see Corten, Taraclia . For the village in Turkey, see Çörten, Altınyayla
"A 606" redirects here. For other uses, see A-606
Texture of a sheet of Cor-Ten after being exposed to the elements for 5 years. The rust can form unevenly based on the composition of the metal.Weathering steel, often referred to by the genericised trademark COR-TEN steel and sometimes written without the hyphen as corten steel, is a group of steel alloys which were developed to eliminate the need for painting by forming a stable external layer of rust.
U.S. Steel (USS) holds the registered trademark on the name COR-TEN.[1] The name COR-TEN refers to the two distinguishing properties of this type of steel: corrosion resistance and tensile strength.[2] Although USS sold its discrete plate business to International Steel Group (now ArcelorMittal) in ,[3] it still sells COR-TEN branded material in strip-mill plate and sheet forms.
The original COR-TEN received the standard designation A242 (COR-TEN A) from the ASTM International standards group. Newer ASTM grades are A588 (COR-TEN B) and A606 for thin sheet. All of the alloys are in common production and use.
The surface oxidation generally takes six months to develop, but surface treatments can accelerate this to as little as one hour.[4]
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The history of weathering steels began in the US in s, when steels alloyed with different amounts of copper were exposed to the elements; the research continued into the s and c.' it was discovered that phosphorus content also helps with the corrosion resistance.[5]
In the United States Steel Corporation decided to commercialize the results of their studies and patented a steel with exceptional mechanical resistance, primarily for use in railroad hopper cars, for the handling of heavy bulk loads including coal, metal ores, other mineral products and grain.[6] The controlled corrosion for which this material is now best known was a welcome benefit discovered soon after, prompting USS to apply the trademarked name Cor-Ten. Because of its inherent toughness, this steel is still used extensively for bulk transport, intermodal shipping containers and bulk storage.[7]
Railroad passenger cars were also being built with Cor-Ten, albeit painted, by Pullman-Standard for the Southern Pacific from ,[8] continuing through commuter coaches for the Rock Island Line in .[9]
In , the Moorestown Interchange was built over New Jersey Turnpike at milepost 37.02. This overpass is believed to be the first highway structure application of weathering steel.[11][10] Other states including Iowa, Ohio, and Michigan followed soon after.[12] Those were followed by University of York Footbridge in the United Kingdom in . Since then, the practice of using weathering steel in bridges has expanded to many countries.[13]
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Weathering refers to the chemical composition of these steels, allowing them to exhibit increased resistance to atmospheric corrosion compared to other steels. This is because the steel forms a protective layer on its surface under the influence of the weather.
The corrosion-retarding effect of the protective layer is produced by the particular distribution and concentration of alloying elements in it. It is not yet clear how exactly the patina formation differs from usual rusting, but it's established that drying of the wetted surface is necessary and that copper is the most important alloying element.[5]
The layer protecting the surface develops and regenerates continuously when subjected to the influence of the weather. In other words, the steel is allowed to rust in order to form the protective coating.[14]
The mechanical properties of weathering steels depend on which alloy and how thick the material is.[16][17]
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The original A242 alloy has a yield strength of 50 kilopounds per square inch (340 MPa) and ultimate tensile strength of 70 ksi (480 MPa) for light-medium rolled shapes and plates up to 0.75 inches (19 mm) thick. It has yield strength of 46 ksi (320 MPa) and ultimate strength of 67 ksi (460 MPa) for medium weight rolled shapes and plates from 0.75'1 inch (19'25 mm) thick. The thickest rolled sections and plates ' from 1.5'4 in (38'102 mm) thick have yield strength of 42 ksi (290 MPa) and ultimate strength of 63 ksi (430 MPa). ASTM A242 is available in Type 1 and Type 2. Both have different applications based on the thickness. Type 1 is often used in housing structures, construction industry and freight cars.[18] The Type 2 steel, which is also called Corten B, is used primarily in urban furnishing, passenger ships or cranes.[19]
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A588 has a yield strength of at least 50 ksi (340 MPa), and ultimate tensile strength of 70 ksi (480 MPa) for all rolled shapes and plate thicknesses up to 4 in (100 mm) thick. Plates from 4'5 in (102'127 mm) have yield strength at least 46 ksi (320 MPa) and ultimate tensile strength at least 67 ksi (460 MPa), and plates from 5'8 in (127'203 mm) thick have yield strength at least 42 ksi (290 MPa) and ultimate tensile strength at least 63 ksi (430 MPa).
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Weathering steel is popularly used in outdoor sculptures for its distressed antique appearance. One example is the large Chicago Picasso sculpture, which stands in the plaza of the Daley Center Courthouse in Chicago, which is also constructed of weathering steel. Other examples include Barnett Newman's Broken Obelisk; several of Robert Indiana's Numbers sculptures and his original Love sculpture; numerous works by Richard Serra; the Alamo sculpture in Manhattan, NY; the Barclays Center, Brooklyn, New York;[20] the Angel of the North, Gateshead; and Broadcasting Tower at Leeds Beckett University.[21]
It is also used in bridge and other large structural applications such as the New River Gorge Bridge, the second span of the Newburgh'Beacon Bridge (), and the creation of the Australian Centre for Contemporary Art (ACCA) and MONA.
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It is very widely used in marine transportation, in the construction of intermodal containers[22] as well as visible sheet piling along recently widened sections of London's M25 motorway.
The first use of weathering steel for architectural applications was the John Deere World Headquarters in Moline, Illinois. The building was designed by architect Eero Saarinen, and completed in . The main buildings of Odense University (built '), designed by Knud Holscher and Jørgen Vesterholt, are clad in weathering steel, earning them the nickname Rustenborg (Danish for "rusty fortress"). In , Robert Indiana created a Hebrew version of the Love sculpture made from weathering steel using the four-letter word ahava ('''', "love" in Hebrew) for the Israel Museum Art Garden in Jerusalem, Israel. In Denmark, all masts for supporting the catenary on electrified railways are made of weathering steel for aesthetic reasons.
Building for School of Architecture, part of the KTH Royal Institute of TechnologyWeathering steel was used in for the Highliner electric cars built by the St. Louis Car Company for Illinois Central Railroad. The use of weathering steel was seen as a cost-cutting move in comparison with the contemporary railcar standard of stainless steel. A subsequent order in was built to similar specs, including weathering steel bodies, by Bombardier. The cars were painted, a standard practice for weathering steel railcars. The durability of weathering steel did not live up to expectations, with rust holes appearing in the railcars. Painting may have contributed to the problem, as painted weathering steel is no more corrosion-resistant than conventional steel, because the protective patina will not form in time to prevent corrosion over a localized area of attack such as a small paint failure. These cars were retired by .[23]
Weathering steel was used to build the exterior of Barclays Center, made up of 12,000 pre-weathered steel panels engineered by ASI Limited & SHoP Construction.[24] The New York Times says of the material: "While it can look suspiciously unfinished to the casual observer, it has many fans in the world of art and architecture."[25] In , a new building for the KTH Royal Institute of Technology School of Architecture was completed on its campus. The use of weathering steel helped the futurisitc shapes of the facade fit in well with its much older surroundings and in it was awarded the Kasper Salin Prize.[26]
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Using weathering steel in construction presents several challenges. Ensuring that weld-points weather at the same rate as the other materials may require special welding techniques or material. Weathering steel is not rust-proof in itself: if water is allowed to accumulate on the surface of the steel, it will experience a higher corrosion rate, so provision for drainage must be made. According to the NTSB, lack of drainage is what ultimately led to the Collapse of the Fern Hollow Bridge. Weathering steel is sensitive to humid subtropical climates, and in such environments it is possible that the protective patina may not stabilize but instead continue to corrode. For example, the former Omni Coliseum, built in in Atlanta, never stopped rusting, and eventually large holes appeared in the structure. This was a major factor in the decision to demolish it just 25 years after construction. The same thing can happen in environments laden with sea salt. Hawaii's Aloha Stadium, built in , is one example of this.[27] Weathering steel's normal surface weathering can also lead to rust stains on nearby surfaces.
The rate at which some weathering steels form the desired patina varies strongly with the presence of atmospheric pollutants which catalyze corrosion. While the process is generally successful in large urban centers, the weathering rate is much slower in more rural environments. Uris Hall, a social sciences building on Cornell University's main campus in Ithaca, a small city in Upstate New York, did not achieve the predicted surface finish on its Bethlehem Steel Mayari-R weathering steel framing within the predicted time. Rainwater runoff from the slowly rusting steel stained the numerous large windows and increased maintenance costs.[28] Corrosion without the formation of a protective layer apparently led to the need for emergency structural reinforcement and galvanizing in , less than two years after opening.[29]
The U.S. Steel Tower in Pittsburgh, Pennsylvania, was constructed by U.S. Steel in part to showcase COR-TEN steel. The initial weathering of the material resulted in a discoloration, known as "bleeding" or "runoff", of the surrounding city sidewalks and nearby buildings.[30] A cleanup effort was orchestrated by the corporation once weathering was complete to clean the markings. A few of the nearby sidewalks were left uncleaned, and remain a rust color. This problem has been reduced in newer formulations of weathering steel.[citation needed] Staining can be prevented if the structure can be designed so that water does not drain from the steel onto concrete where stains would be visible.
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When it comes to building a retaining wall, the choice of material is crucial. Among the various options available, steel is a popular choice due to its strength, durability, and versatility. However, not all types of steel are suitable for retaining walls. In this week's MAH Steel blog, we will explore the best steel for retaining walls and help you make an informed decision.
Before we dive into the best steel for retaining walls, let's take a look at the factors that you should consider when selecting a steel for your project:
A retaining wall needs to be able to withstand significant amounts of pressure from the soil behind it. Therefore, the steel used in the wall must have high tensile strength to prevent collapse or deformation.
Retaining walls are often exposed to moisture and salt, which can cause corrosion and weaken the steel over time. Therefore, it's essential to choose a steel that has good corrosion resistance.
A retaining wall is expected to last for many years, so the steel used in its construction must be durable and able to withstand the elements.
While it's important to prioritise strength, corrosion resistance, and durability, it's also essential to consider the cost of the steel. The chosen steel should provide the necessary characteristics at a reasonable price, which at MAH Steel, we offer great prices across all of our steel products.
Now that we've discussed the factors to consider, let's take a look at the best steel for retaining walls:
Galvanised steel has a layer of zinc coating, which provides excellent corrosion resistance. It's also strong and durable, making it a popular choice for retaining walls. Galvanised steel is available in various thicknesses and steel fabricators can bend or shape it to fit the required dimensions.
Stainless steel is another great option for retaining walls. It's highly resistant to corrosion and has a long lifespan. There are different grades of stainless steel available, so make sure to choose one that meets your budget and has the necessary strength and durability. Stainless steel is also easy to clean and maintain, making it a great choice for retaining walls in high-traffic areas.
Corten steel is a type of weathering steel that's designed to withstand exposure to the elements. It has a natural rust finish that blends in with the surrounding landscape, making it a popular choice for outdoor structures like retaining walls. Corten steel is strong, durable, and resistant to corrosion, making it an excellent choice for retaining walls in harsh environments.
Structural steel is a high-strength, low-alloy steel that's commonly used in construction projects. It's strong, durable, and resistant to corrosion, making it a great choice for retaining walls. Structural steel can be customised to fit the required dimensions and is available in various thicknesses.
Choosing the right steel for a retaining wall is critical to ensure its stability and longevity. Galvanised steel, stainless steel, corten steel and structural steel are among the best options for retaining wall steel types. Each of these steels offers unique benefits, including high strength, corrosion resistance, durability, and cost-effectiveness. By considering the factors mentioned above and selecting the appropriate steel, you can build a retaining wall that will stand the test of time.
Should you be in the process of planning a project that involves the construction of a retaining wall or any other steel fabrication endeavour, we invite you to reach out to us at MAH Steel. Our commitment to providing the best prices and unparalleled service in the industry makes us the ideal partner for your upcoming construction or fabrication needs.
At MAH Steel, we understand the importance of quality, precision, and efficiency in all projects, and we are well-equipped to meet and exceed your expectations. Our team of experienced professionals is dedicated to delivering exceptional results. We ensure that your project is not only cost-effective, but also completed to the highest standards. By choosing MAH Steel, you can rest assured that your project will benefit from our extensive expertise, state-of-the-art technology, and a steadfast commitment to client satisfaction. Our mission is to be your trusted partner in steel fabrication, offering competitive pricing and a level of service that sets the industry standard.
When you engage with MAH Steel, you're not just selecting a steel fabrication service. You're choosing a reliable, professional partner that values your goals and delivers on its promises.
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