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Sample Bridges - High Performance Materials - Conclusions - - - PDF document

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Kentucky Transportation Center CE 120 Introduction to Civil Engineering Wednesday, February 5, 2014 University of Kentucky Lexington, KY T HE B RENT- S PENCE B RIDGE High Performance Materials for Bridge Structures Program Strengthening

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SLIDE 1

High Performance Materials for Bridge Strengthening

Department of Civil Engineering

University of Kentucky

Kentucky Transportation Center CE 120 – Introduction to Civil Engineering Wednesday, February 5, 2014 Lexington, KY

by The Others and Issam Harik

Outline

  • Introduction
  • High Performance Materials
  • Conclusions
  • Acknowledgment

Outline

  • Introduction
  • High Performance Materials
  • Conclusions
  • Acknowledgment

Structures Program

Program Manager: Issam Harik

Kentucky Transportation Center University of Kentucky

 Field Testing and Modeling  Seismic Evaluation  Vessel Impact on Bridges  Remote Sensing  Hazard Mitigation  High Performance Materials

 Homeland Security

Structures Program

Projects 1996 – Present

Sample Bridges

THE BRENT-SPENCE BRIDGE

US 51 Bridge Over the Ohio River

Wickliffe, KY to Cairo, IL

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SLIDE 2

Henderson, KY to Evansville, IN

Owensboro Bridge

The Maysville Bridge

Field Testing

3-D Accelerometers

Field Testing Field Testing Field Testing

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SLIDE 3
  • 0.4
  • 0.2

0.2 0.4 0.6 0.8 1 1.2 500 1000 1500 2000 FEM Field Testing Mode Shape Magnitude Bridge Longitudinal Distance

3-D View Plan 1st Vertical Mode Elevation

FE Modeling and Calibration

3-D View Plan 1st Transverse Mode (+Torsion) Elevation

  • 0.2

0.2 0.4 0.6 0.8 1 1.2

  • 100

100 200 300 400 500 600 700 FEM Field Testing Mode Shape Magnitude Bridge longitudinal Distance

FE Modeling and Calibration

Remote Monitoring and Intelligent Sensing

Allen County Bridge

Allen County Bridge

Monitoring Locations

6” thick, #10 crushed stone

Pressure cell

1.5” dia. conduit

North

@ Pier #1

12’-0” 0’-6” 6’-0” 12’-0”

7 1 6 5 4 3 2

6’-0”

Allen County Bridge

Plan View Elevation View

Instrumentation under Spread Footing

Allen County Bridge

Pressure Cell Layout

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SLIDE 4

Eastbound I-64 (Towards Lexington) Eastbound US60 (Towards Versailles) Westbound US60 (Towards Frankfort) This outer girder on Eastbound I-64 over Eastbound US60 gets hit by trucks exceeding the height restriction due to low clearance at that station

I-64 Parallel Bridges over US60

SPAN 2 SPAN 1 SPAN 3 North Eastbound US 60 (To Versailles) Westbound US 60 (To Frankfort) Westbound I-64 (To Louisville) Eastbound I-64 (To Lexington) The outer girder on Eastbound I-64 over Eastbound US60 gets hit by trucks exceeding the height restriction due to low clearance at that location This girder in Span 3 on Westbound I-64 underwent excessive deflection and vibration under truck loading. Cracks had formed on this girder and the adjacent girders. This girder in Span 1 on Westbound I-64 underwent excessive deflection and vibration under truck loading. Cracks had formed on this girder and the adjacent girders.

I-64 Parallel Bridges over US60

North

Possible Instrumentation Plan

Westbound I-64 (To Louisville) Eastbound I-64 (To Lexington) Eastbound US60 (To Versailles) Westbound US60 (To Frankfort) Strain gage Crack sensor (Span 1) Crack Sensor Strain gage (Span 3) Camera #1 Camera #2 Vehicle Height Sensor Impact Detector Note: Depending on additional cost, instrumentation on Span 1 may not be placed

BARGE IMPACT ON BRIDGES

Pier B Pier C Pier D

KY IN

Instrumentation Plan - US 41N Bridge Instrumentation Plan - US 41N Bridge

Detect Impact on Pier B, or C, or D Location of Instrumentation

Outline

  • Introduction
  • High Performance Materials
  • Conclusions
  • Acknowledgment

High Performance Materials

FRP Components

(FRP = Fiber Reinforced Polymer)

FRP COMPOSITES

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SLIDE 5

Glass FRP Bar

FRP Composite Materials

Reinforcements Fillers Additives Resins

FRP Composite Materials

Resins

Reinforcements Fillers Additives Thermosetting Polymers

  • Polyester

(FRP Components)

  • Epoxy

(Wet Layup)

  • Vinylester (FRP Rebars)
  • Commonly used in CE applications
  • Cannot be reversibly softened
  • Cannot be bent on site

Thermoplastics

  • Polyurethane
  • Thermoplastic
  • Phenolics
  • Not currently used in CE applications
  • Polymer can be reversibly softened

Resins

Reinforcements

Fillers Additives

  • Carbon
  • Glass
  • Aramid
  • Boron
  • Nylon
  • Polyester
  • Polyethylene

FRP Composite Materials

Resins Reinforcements

Fillers

Additives

  • calcium carbonate
  • clay
  • talc
  • aluminum trihydrate
  • silica
  • micro spheres
  • mica

FRP Composite Materials

Function of Fillers

  • Improves mechanical

properties

  • Improves surface finish
  • Improves processibility
  • Lowers total part cost
  • Improves dimensional

stability

  • Reduces shrinkage

Resins Reinforcements Fillers

Additives

  • catalysts &

promoters

  • inhibitors
  • release agent
  • pigments
  • uv absorber
  • fire retardant

FRP Composite Materials

Function of Additives

  • Modifies cure rate
  • Extends shelf life
  • Prevents shrinkage
  • Improves weatherability
  • Viscosity reduction
  • Adds color
  • Reduces porosity

Fabrication Processes

Hand Lay-Up Pultrusion Spray-Up Molding Other

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SLIDE 6

FRP BARS

(Thermosetting Polymers)

FRP BARS

(Thermoplastics)

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SLIDE 7

FRP APPLICATIONS

2007 Full Carbon Fiber Road Racing Bike Dura ACE

2011 Ducati Diavel Carbon Audi Carbon Skis

King Cobra Carbon CB Iron set Golf Club

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SLIDE 8

Total Carbon Element Tennis Racket (TB016)

Boats

F-117 Nighthawk

Stealth Bomber Stiletto Stealth Ship Sea Shadow Stealth Boat

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SLIDE 9

Sea Shadow Stealth Boat Stealth Submarine

Ghost

Supercavitating Ship for the Navy

All Carbon Fiber M-14/M1A Rifle

Walther P22 Carbon Fiber Frame 3.4" 22LR

THE CLEAR CREEK BRIDGE

PULTRUDED HYBRID CARBON/GLASS FRP I-BEAMS

Bridge Design Parameters

  • Pedestrian Load of 85 psf ~ 4 kPa
  • Live load deflection limit of

L/180 (4 inches ~100 mm)

60ft ~ 20m 6f t ~ 2m 6ft ~ 2m

I-Girder Steel Bridge

18" 6" W18x46 Section 2 Girders Required E = 29,000 ksi ~ 200 GPa 60ft ~ 20m 6ft ~ 2m 6” ~ 153mm 18“ ~ 460mm

GFRP Beam Requirements

30 GFRP Girders required using 18" (~460mm) deep sections E = 2500 ksi ~ 17 GPa (1/12 Esteel) 6ft ~ 2m

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SLIDE 10

GFRP Beam Requirements

6ft ~ 2m 8 Girders required using 24" (~ 610mm) sections E = 2500 ksi ~ 17 GPa (1/12 Esteel)

Carbon and Glass Fibers

Laboratory Testing Bridge Fabrication Bridge Assembly Bridge Construction Bridge Construction Bridge Construction Bridge Construction

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SLIDE 11

Bridge Construction Bridge Construction Bridge Construction

GFRP Cables

Bridge Construction Bridge Construction

Opening Ceremony

November 14,1996

Clear Creek Bridge, Kentucky

Load Test

Bridge Visit By International Researchers Bridge Visit By Japanese Researchers

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SLIDE 12
  • Longest FRP Girder Bridge
  • First Hybrid FRP Bridge
  • First application of Inverted

Cable Stay THE SWINGING BRIDGE PULTRUDED GFRP DECK Johnson County, KY

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SLIDE 13

Rebars

  • Fiber Reinforced Polymer (FRP)
  • Stainless Steel Clad (SS)
  • Microcomposites (MMFX)
  • Epoxy Coated Steel (ECS)

50 100 150 200 250 300 0.0E+00 1.0E-02 2.0E-02 3.0E-02 4.0E-02 5.0E-02 6.0E-02 7.0E-02 Strain (in/in) Stress (ksi) MMFX Steel Stainless Steel Clad ECS Steel CFRP Rebar

Stress/Strain Curves of Various Rebars

GFRP Rebar

Glass FRP Rebars

Roger’s Creek Deck, Kentucky - 1997

Second Bridge in the US With GFRP Bars

Clark County Bridge, Kentucky - 2002

First Bridge in the US With CFRP Bars

Clark County Bridge

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SLIDE 14

MMFX SSC

Scott County Bridge, KY

MMFX and Stainless Steel Clad Bars in Deck

First Deployment of MMFX Steel Bars in the World First Deployment of Stainless Steel Clad Bars in the US

FRP Piles US NAVY Platform

Panama City, Florida

Acoustic test pool 359 ft by 258 ft, 40 ft deep (magnetically clean)

FRP & Concrete Piles FRP & Concrete Piles FRP & Concrete Piles

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SLIDE 15

Bridge Decks

  • FRP Deck
  • Aluminum Deck

FRP Bridge Decks

Creative Pultrusions (CP) Hardcore Composites Infrastructure Composites International

ICI - CCTI

Glass FRP Bars Glass FRP Tubes Concrete

Diversified Fabricators, Inc.

End View

DFI 4 Pultruded panels #5 GFRP bars @ ~ 3 in. o.c.

First Salem Bridge Dayton, Ohio Placement of FRP Deck

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SLIDE 16

Aluminum Bridge Decks

KY 974 Bridge Over Howard Creek Clark County, KY Aluminum Bridge Deck

Fabricated in Holland

KY 974 Bridge Over Howard Creek Clark County, KY

Aluminum Deck Placement Aluminum Deck Placement Bridge Ready for Traffic After 2 Hours

Deck Connection to Steel Girders KY 974 Bridge Over Howard Creek Clark County, KY

Asphalt Topping

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SLIDE 17

KY 270 Bridge Webster County, KY

July 30, 2009

KY 270 Bridge Webster County, KY

Aluminum Deck Placement

Bridge Retrofit

  • Carbon FRP Fabric
  • High Strength Steel Fabric (Hardwire)
  • Carbon FRP Laminates

 CFRP Fabric

STRENGTHENING

WITH CFRP CLOTH/FABRIC

CFRP Fabric Test Specimens

Ultimate Load = 3.25 kip

1” 1” hCFRP = 0.0066”

wCFRP = 0.0051 lb/ft wSteel = 0.19 lb/ft ≈ 37 wCFRP

hSteel = 0.056” ≈ 8.5 hCFRP

CFRP Fabric vs. Steel

45o

Beam Strengthening

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SLIDE 18

Bridge on KY 3297 over Little Sandy River Carter County, Kentucky Shear Cracks in P/C Box Beams

Cracks Growing at an Alarming Rate

Severe Shear Cracks

Original Solution

Replace the Superstructure

  • Cost: ~ $600,000
  • Close Bridge to Traffic

Alternate Solution

Use CFRP Fabric

  • Cost: $105,000

(Design, Repair, and 3-yrs Monitoring)

  • Bridge Remains Open to Traffic

(Except for Heavy Trucks)

Step 1:

Surface Preparation

Step 2:

Crack Injection and Filling of Voids

Step 3:

Apply Primer

Step 4:

Apply Carbon Fabric

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SLIDE 19

Step 5:

CFRP Fabric on Outside Face Painted to Match Concrete Color Scaffolding Used for Monthly Bridge Monitoring

Bridge Monitoring (10/01 to 12/06)

CFRP Fabric on Inside Faces of the Beams Was Not Painted to Match Concrete Color Crack Monitor

No Crack Movement has Occurred Since Repair Was Completed in October 2001

Crack Monitor on Inside Beam Face

  • Cost Effective: $105,000 for Repair vs.

$600,000 for Replacement

  • Repair is Effective: No Crack Movement

Since Repair was Completed in October 2001

  • No Traffic Control or Disruption

Conclusion

Associated Press

November, 2001

The State Journal, December, 2001 The Daily Independent

November, 2001 I-65 North-South Expressway, Jefferson County KENTUCKY, USA

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SLIDE 20

I-65 Elevated Expressway

PIER 6 at Main & Hancock ST

Retrofit Locations

PC spans between Broadway & Chestnut PIER 4 at Jefferson & Preston ST PIER I-65 over Muhammad Ali Blvd. PC spans between Jacob & Gray ST

Retrofit Locations

PC spans between Jacob & Gray ST Fix Fix Exp. Exp. PC girders

Cracks at piers with fixed restraints.

Bridge deck

I-65 Elevated Expressway Louisville, KY Steel rebars Embedment length of steel rebars Pier cap PC girder Crack Cracks in prestressed concrete girders near supports Instrumentation on Span 117 (Pier 8) on Southbound I-65 Expressway BEAM 6 BEAM 7

LVDT 1 (H) LVDT 2 (V) LVDT 3 (H) LVDT 5 (V) THERMOMETER AND DATA ACQUISITION SYSTEM

  • 10

10 20 30 40 50 60 70 80 400 800 1200 1600 Elapsed Time (Hours) Relative Horizontal Movement (x 10

  • 3 in)

LVDT 3 10 20 30 40 50 60 70 80 90 100 400 800 1200 1600 Elapsed Time (Hours) Temperature (

  • F)

Crack is closing

LVDT 3 (H) As of May 1, 2004 Beam 7 Span 117

  • 10

10 20 30 40 50 60 70 80 400 800 1200 1600 Elapsed Time (Hours) Relative Vertical Movement (x 10

  • 3 in)

LVDT 2 10 20 30 40 50 60 70 80 90 100 400 800 1200 1600 Elapsed Time (Hours) Temperature (

  • F)

PC beam moving downward relative to pier cap

LVDT 2 (V) as of May 1, 2004: Beam 6 Span 117

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SLIDE 21
  • 80
  • 60
  • 40
  • 20
20 40 60 80 100 2000 4000 6000 8000 10000 Elapsed time (Hr)
  • Rel. Hor. Move. (x10
  • 3 in)
LVDT 1 10 20 30 40 50 60 70 80 90 100 2000 4000 6000 8000 10000 Elapsed time (Hr) Temperature (
  • F)

Beam 6 LVDT 1 2/11/20 04 2/14/20 05 Crack is closing

  • 80
  • 60
  • 40
  • 20
20 40 60 80 100 500 1000 1500 2000 Elapsed time (Hr)
  • Rel. Hor. Move. (x10
  • 3 in)
LVDT 1 10 20 30 40 50 60 70 80 90 100 500 1000 1500 2000 Elapsed time (Hr) Temperature (
  • F)

9/4/200 6 Period during which design and construction

  • f retrofit took
place 10/31/2 006

Horizontal Movement

Before the Repair After the Repair

Vertical Movement

Before the Repair After the Repair

10 20 30 40 50 60 70 80 90 100 2000 4000 6000 8000 10000 Elapsed time (Hr) Temperature (
  • F)
10 20 30 40 50 60 70 80 90 100 500 1000 1500 2000 E lapsed time (Hr) Temperature (
  • F)
  • 10
  • 8
  • 6
  • 4
  • 2
2 4 6 8 10 2000 4000 6000 8000 10000 Elapsed time (Hr)
  • Rel. Ver. Move. (x10
  • 3 in)
LVDT 2

Beam 6 LVDT 2 2/11/200 4 2/14/200 5 PC beam moving downward relative to pier cap

  • 10
  • 8
  • 6
  • 4
  • 2
2 4 6 8 10 500 1000 1500 2000 Elapsed time (Hr)
  • Rel. Ver. Move. (x10
  • 3 in)
LVDT 2

9/4/2006 10/31/20 06 Period during which design and construction of retrofit took place PIER I-65 over Muhammad Ali Blvd.

Repair at Pier (I-65 over Muhammad Ali Blvd.)

Repair Using Triaxial CFRP Fabric

First Application of Triaxial Fabric on Bridges Bridge Retrofit Using Tri-axial CFRP Fabric in Simpson County, KY

Transportation Research Board Annual Meeting January 13 - 17, 2013

Tri-axial CFRP Fabric Application

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SLIDE 22

Repair Completed Repair Completed

High Strength Steel Fabric (Hardwire)

Retrofit Measures: Hardwire Steel FRP

Second Bridge in the US With Steel Wire Fabric Strengthening With CFRP Laminates Testing of Beam Strengthened With CFRP Laminates Testing of Beam Strengthened With CFRP Laminates

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SLIDE 23

Louisa-Fort Gay Bridge

Over the Tug Fork and Big Sandy Rivers

Coal Truck Weigh in Motion Data: 225,000 lb (100 Metric Ton)

Louisa-Fort Gay Bridge

Over the Tug Fork and Big Sandy Rivers

25k 50k 50k 50k 50k

Flexural Cracks in RC Spans 4-6-7 Louisa-Fort Gay Bridge

Flexural Cracks RC Girder Diaphragms

G 1 G 2 G 3 G 10 G 4 G 5 G 6 G 7 G 8 G 9 P 3 P 4 P 5 P 6 P 7 S 4 S 5 S 6 S 7 FORT GAY (WV) LOUISA (KY)

Number of CFRP Laminates Required for Flexural Strengthening

1-Strip 1-Strip 3-Strips 3-Strips 2-Strips 2-Strips 2-Strips 2-Strips 2-Strips 2-Strips 2-Strips 2-Strips 4-Strips 4-Strips 4-Strips

Application of CFRP Laminates to Span 4

1-Laminate 3-Laminates 2-Laminates

Technology Exchange with Perm, Russia

Tishkovka Bridge Perm, Russia

1st T-girder 5th T-girder

Need to Increase Strength of Girder 1 and Girder 5 by 15%

Tishkovka Bridge Perm, Russia

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SLIDE 24
  • Bridge Retrofitted With CFRP

Laminates

  • Production of CFRP Laminates
  • Retrofit Design With CFRP Laminates

Firsts in the Eastern Block Countries

Retrofit of the KY 32 Bridge in Scott County, KY

Steel Girders Strengthened With Ultra High Modulus CFRP Laminates

 Ultra High Modulus:

ECFRP > 2ESteel [or ECFRP > 400 GPa (58000 ksi)]

 High Modulus:

ESteel [or 200 GPa ] < ECFRP < 2ESteel [or 400 GPa ] ESteel [or 29000 ksi] < ECFRP < 2ESteel [or 58000 ksi]

High Modulus CFRP Laminates

 Intermediate Modulus:

0.5ESteel [or 100 GPa] < ECFRP < ESteel [or 200 GPa] 0.5ESteel [or 14500 ksi] < ECFRP < ESteel [or 29000 ksi]

 Low Modulus:

ECFRP < 0.5ESteel [or 100 GPa (14500 ksi)]

Introduction

Ultra High Modulus CFRP Plates (Modulus 450 GPa /65250 ksi)

Takiguchi Bridge, 2008 (Tokyo, Japan)

KY 32 Bridge KY 32 Bridge Ultra High Modulus CFRP Laminate

CFRP Laminate with peel ply Epoxy

50 171 50 1.2mm (0.0474”) thick ultra high modulus CFRP plate 1.2mm (0.0474”) thick ultra high modulus CFRP plate All dimensions are in millimeters 56 27

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SLIDE 25

Lexington Herald Leader April 22, 2010

Second Bridge in the World With UHM CFRP Laminates

Limitations

  • f Current

Retrofit Methods

State Highway 92 Bridge, Pottawattamie County, Iowa

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SLIDE 26

KY32 Bridge over Lytles Creek in Scott County

60 ft

Louisa-Fort Gay Bridge

58.3 ft

Louisa-Fort Gay Bridge Louisa-Fort Gay Bridge

90 ft

US150 Bridge, Washington County, KY

CatStrong

CFRP Rod Panels Developed at U. of KY

CFRP rods

Fiberglass mesh backing 12” 6” 6” 48”

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SLIDE 27

Designation Diameter, d (in) Rod area (x10-3 in2) Rod Spacing, s (in) Bars per panel Weight (lb./panel) Strength (kip/ft.) CRP70 0.078 4.78 0.25 48 0.66 73.4 CRP90 0.088 6.08 0.25 48 0.81 93.4 CRP110 0.098 7.54 0.25 48 1.00 115.8 CRP145 0.136 14.53 0.375 32 1.30 148.7 CRP195 0.156 19.11 0.375 32 1.71 195.7 Carbon panel placement d s CFRP rod t Epoxy Concrete

CatStrong

CRP-195 vs. Steel

1.0 ft 1.0 ft tC=0.156 in tS = 0.28 in WS = 11.45 lb/ft ≈ 26 WC WC = 0.43 lb/ft

Ultimate Load = 195 kip

CRP-195 vs. CFRP Fabric

1 ft 1 ft tC =0.156 in tF =0.16 in WF = 0.125 lb/ft ≈ 0.3 WCRP WC = 0.43 lb/ft

Ultimate Load = 195 kip

(without epoxy) (without epoxy) (with epoxy)

CRP-195 vs. CFRP Laminate

1 ft 4 in tC =0.156 in tL=0.047 in WC = 0.43 lb/ft

Ultimate Load = 195 kip

4 in 2.4 in WL= 0.35 lb/ft

(without epoxy) (without epoxy for 2.6 laminates)

CRP-195 vs. HARDWIRE

1 ft 1 ft tC =0.156 in tH =0.141 in WH = 1.43 lb/ft ≈ 3.3 WCRP WC = 0.43 lb/ft

Ultimate Load = 195 kip

(without epoxy) (without epoxy)

CRP 195 Strength = 195,700 lbs/ft Type 1 Truck W = 40,000 lbs Type 3 Truck W = 73,500 lbs Type 4 Truck W = 80,000 lbs

CatStrong Field Applications

Repair of the KY218 Bridge Over Blue Springs Creek, Hart County, KY

First Application of CatSrong CRP80 (week of September 19, 2011)

Step 2: Application of CRP80 on resin Step 3: Application of resin coat on CRP80 Girder strengthened with CRP80 Step 1: Application of resin

  • n concrete girder
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SLIDE 28

Caldwell Road over Blue Grass Parkway Caldwell Road over Blue Grass Parkway

Retrofit of Impacted Girder

  • n the Sunnyside-Gotts Road over I-65

Impacted Girder

Impacted Girder

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SLIDE 29

Day 1,2: Preparation of Damaged Zone Day 3: Bonding Agent on Steel and Concrete Day 3: Formwork for Repair Mortar Day 4: Patching of Defects Day 5: Crack Injection Day 6: Grinding of Crack Injection Ports Day 6: Sand Blasting of Retrofit Surface Day 6: CatStrong CRP 195 Application Day 6: CFRP Fabric Application

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SLIDE 30

Day 6 (Dawn of Day 7): Retrofitted Zone Retrofitted Girder Stronger Than Original Girder

KY 81 Bridge, McLean County, KY Removal of Loose Concrete, Rust From Steel, etc. (8/9/12) Beam Brought Back to Original Shape (8/10/12) Application of CatStrong (9/17/12) Application of CFRP Fabric (9/18/12) Beam After Repair (9/18/12)

(Repaired beam is stronger than the original beam when the bridge was first opened to traffic)

Outline

  • Introduction
  • Space Age Material
  • Conclusions
  • Acknowledgment

Conclusion

  • Structural repair is an area where HP

Materials

  • Health Monitoring
  • HP Materials are now viable alternative

construction material

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SLIDE 31

Outline

  • Introduction
  • High Performance Materials
  • Conclusions
  • Acknowledgment

Personnel 1996 – Present

Structures Group

 36 Visiting Professors and Scholars  14 UK Professors  35 Staff  12 Ph.D. Students  45 M.S. Students  37 U.G. Students  12 High School Students

Questions?

Thank You and Have a Nice Day