Falling parts can endanger human lives. The cause is the so-called hydrogen-induced brittle fracture, which often occurs with a time lag after installation. Today, we know that there are three coherent factors: a critical hydrogen charge, a critical material state, and a critical stress state.
Steel profile sheets which are not exposed to the elements,
may be fixed in industrial lightweight construction using
screws made of case hardened steel. Under certain
conditions however, there is the risk of hydrogen-induced brittle
fracture, in which the screw head breaks off without a recognisable
reason. Through the use of sealing washers, brittle
fracture can be effectively avoided.
Industrial and commercial buildings, which are manufactured
in lightweight construction, generally consist of steel skeleton
constructions that are planked with trapezoidal profiles of
different thicknesses. The steel profile plates are screwed directly
to the steel girders with self-drilling or thread-tapping screws.
Screws made of case-hardened, zinc-plated carbon steel can
be used for fastening of the supporting elements and the loadbearing
shell. A higher grade material, such as corrosion
resistant stainless steel, is not necessary, since the load-bearing
shell is usually still provided with an insulating layer and
then closed with a cover shell. As a result, the screw joint is
permanently protected from weather influences.
Errors during the construction phase with serious consequences
The screw head suddenly breaks off. For no apparent reason. The consequences are incalculable damages to the building.
Example of an optimal fixing with sealing washer of the load-bearing shell and the cover shell
In the daily routine, many construction sites do not run as originally planned: delivery delays, changes in planning or difficult weather conditions often lead to unintentional delays between the individual construction phases. In detail this could mean, that the steel screws are weather exposed over several days or weeks, even though the material is not optimised for this. Things become dangerous when the screws have been fastened in the steel girder with a high tightening torque or are fixed at an angle. Then the failure of the screw happens without previous visible deformations or corrosion. Therefore, it is not possible to predict the time of fracture. Damages can occur months after completion of the construction work. The often serious consequences might include closed construction sites, high complaints costs and damages to the company image. In addition a danger to human life, by falling components, can not be ruled out.
The collapse of the Berlin Congress Hall is one of the most spectacular damage cases caused by so-called hydrogen embrittlement. In 1980 the 600 ton southern roof brim above the main entrance of the hall collapsed. Many people were injured and a 27-year-old man was killed in the accident. In the analysis, experts discovered a whole series of design errors in the construction.
The collapse of the Berlin Congress Hall is one of the most spectacular damage cases caused by so-called hydrogen embrittlement. In 1980 the 600 ton southern roof brim above the main entrance of the hall collapsed. Many people were injured and a 27-year-old man was killed in the accident. In the analysis, experts discovered a whole series of design errors in the construction.
Connection without sealing washer
Brittle fracture has occurred
Connection with sealing washer
SEM image of the fracture surface of a lowdeformation fracture of a micro screw in the region of the under-head radius.
In the detailed view of the upper picture, gaping grain boundaries, intercrystalline split fractures and zones with linear residual ductility (crow’s feet) are visible on the split fractures
How does hydrogen-induced brittle fracture occur?
Influencing factors and avoidance measures
Prerequisites for hydrogen-induced brittle fractures are
- the presence of a hydrogen supply
- during the manufacturing process
- while using the screw at the construction site - the material condition
- the mechanical loading of the screw
The risk of a hydrogen-induced brittle fracture is only present when all three parameters are critical.
Optimisation in the manufacturing process
(at the EJOT plant)
In simple terms, the release of hydrogen is minimised in the finishing process during surface treatment. The heat treatment ensures optimum core and edge hardness as well as sufficient toughness of the material. In addition, the hydrogen loading is further reduced by hydrogen annealing. Before delivery, the screws are subjected to a load test to minimise the risk.