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

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 Program Manager: Issam Harik by The Others and Issam Harik Department of Civil Engineering University of Kentucky Kentucky Transportation Center Structures Program Outline Projects 1996 – Present  Field Testing and Modeling - Introduction  Seismic Evaluation - High Performance Materials  Vessel Impact on Bridges - Conclusions  Remote Sensing  Hazard Mitigation - Acknowledgment  High Performance Materials  Homeland Security Outline US 51 Bridge Over the Ohio River - Introduction Sample Bridges - High Performance Materials - Conclusions - Acknowledgment Wickliffe, KY to Cairo, IL

Field Testing Henderson, KY to Evansville, IN 3-D Accelerometers Owensboro Bridge Field Testing The Maysville Bridge Field Testing Field Testing

Allen County Bridge FE Modeling and Calibration Plan 1.2 FEM 1 Mode Shape Magnitude Field Testing 0.8 0.6 0.4 3-D View 0.2 0 -0.2 Monitoring Locations -0.4 0 500 1000 1500 2000 Bridge Longitudinal Distance 1 st Vertical Mode Elevation Allen County Bridge FE Modeling and Calibration North Pressure cell @ Pier #1 12’-0” Plan 6’-0” 0’-6” 1.5” dia. conduit Allen County Bridge 1.2 FEM 1 4 Field Testing 7 Mode Shape Magnitude 6’-0” 0.8 5 12’-0” 0.6 1 3 0.4 3-D View 2 0.2 6 6” thick, #10 crushed stone 0 Elevation View Plan View -0.2 -100 0 100 200 300 400 500 600 700 Bridge longitudinal Distance Instrumentation under Spread Footing 1 st Transverse Mode (+Torsion) Elevation Allen County Bridge Remote Monitoring and Intelligent Sensing Pressure Cell Layout

Possible Instrumentation Plan Outline North Eastbound US60 Westbound US60 ( To Versailles ) ( To Frankfort ) Crack Sensor Strain gage - Introduction Crack sensor Strain gage (Span 3) (Span 1) - High Performance Materials Note: Depending on additional cost, instrumentation on Westbound I-64 ( To Louisville ) Span 1 may not be placed - Conclusions - Acknowledgment Camera #1 Eastbound I-64 ( To Lexington ) Vehicle Height Sensor Impact Detector Camera #2 I-64 Parallel Bridges over US60 High Performance Materials SPAN 3 SPAN 2 SPAN 1 FRP Components Eastbound I-64 ( Towards Lexington ) (FRP = Fiber Reinforced Polymer) Westbound US60 ( Towards Frankfort ) Eastbound US60 This outer girder on Eastbound I-64 over ( Towards Versailles ) Eastbound US60 gets hit by trucks B ARGE I MPACT ON B RIDGES exceeding the height restriction due to low clearance at that station I-64 Parallel Bridges over US60 FRP C OMPOSITES Instrumentation Plan - US 41N Bridge Instrumentation Plan - US 41N Bridge North Eastbound US 60 Westbound US 60 ( To Versailles ) ( To Frankfort ) Location of Instrumentation KY This girder in Span 1 on Westbound I-64 This girder in Span 3 on Westbound I-64 underwent excessive deflection and vibration underwent excessive deflection and vibration under truck loading. Cracks had formed on under truck loading. Cracks had formed on this girder and the adjacent girders. this girder and the adjacent girders. IN Westbound I-64 (To Louisville) Eastbound I-64 (To Lexington) Pier D Pier C Pier B Detect Impact on Pier B, or C, or D 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

FRP Composite Materials FRP Composite Materials Additives Resins Additives Resins Fillers Reinforcements Fillers Reinforcements Thermosetting Polymers Thermoplastics Function of Additives • catalysts & promoters  Polyester  Polyurethane • Modifies cure rate (FRP Components) • Extends shelf life • inhibitors  Epoxy  Thermoplastic (Wet Layup) • release agent • Prevents shrinkage  Vinylester (FRP Rebars)  Phenolics • pigments • Improves weatherability - Commonly used in CE applications - Not currently used in CE applications • uv absorber • Viscosity reduction - Cannot be reversibly softened - Polymer can be reversibly softened • fire retardant - Cannot be bent on site • Adds color • Reduces porosity Glass FRP Bar FRP Composite Materials Fabrication Processes Reinforcements Resins Fillers Additives  Carbon Hand Lay-Up Pultrusion  Glass  Aramid  Boron Spray-Up Other Molding  Nylon  Polyester  Polyethylene FRP Composite Materials FRP Composite Materials Fillers Resins Reinforcements Additives Function of Fillers Resins Reinforcements Fillers Additives • calcium carbonate • Improves mechanical • clay properties • talc • Improves surface finish • aluminum trihydrate • Improves processibility • silica • Lowers total part cost • micro spheres • Improves dimensional • mica stability • Reduces shrinkage

FRP B ARS (Thermosetting Polymers) FRP B ARS (Thermoplastics)

2011 Ducati Diavel Carbon F RP A PPLICATIONS Audi Carbon Skis 2007 Full Carbon Fiber King Cobra Carbon Road Racing Bike Dura ACE CB Iron set Golf Club

Stealth Bomber Total Carbon Element Tennis Racket (TB016) Stiletto Stealth Ship F-117 Nighthawk Boats Sea Shadow Stealth Boat

Sea Shadow Stealth Boat Bridge Design Parameters All Carbon Fiber M-14/M1A Rifle 60ft ~ 20m 6f t ~ 2m 6ft ~ 2m  Pedestrian Load of 85 psf ~ 4 kPa  Live load deflection limit of L/180 (4 inches ~100 mm) Stealth Submarine I-Girder Steel Bridge 60ft ~ 20m 6ft ~ 2m 6" W18x46 Section 6” ~ 153mm 2 Girders Required 18“ ~ 460mm Walther P22 Carbon Fiber 18" Frame 3.4" 22LR E = 29,000 ksi ~ 200 GPa GFRP Beam Requirements 6ft ~ 2m T HE C LEAR C REEK B RIDGE Ghost P ULTRUDED H YBRID 30 GFRP Girders required using 18" (~460mm) deep sections Supercavitating Ship for the Navy C ARBON/ G LASS FRP I-B EAMS E = 2500 ksi ~ 17 GPa (1/12 E steel )

Bridge Fabrication Bridge Construction GFRP Beam Requirements 6ft ~ 2m 8 Girders required using 24" (~ 610mm) sections E = 2500 ksi ~ 17 GPa (1/12 E steel ) Bridge Assembly Bridge Construction Carbon and Glass Fibers Laboratory Testing Bridge Construction Bridge Construction

Bridge Construction Bridge Construction Load Test Bridge Visit By Bridge Construction Bridge Construction International Researchers Bridge Visit By Bridge Construction Opening Ceremony Japanese Researchers November 14,1996 GFRP Cables Clear Creek Bridge, Kentucky

- Longest FRP Girder Bridge - First application of Inverted Cable Stay - First Hybrid FRP Bridge T HE S WINGING B RIDGE P ULTRUDED GFRP D ECK Johnson County, KY

Rebars - Fiber Reinforced Polymer (FRP) First Bridge in the US With - Stainless Steel Clad (SS) CFRP Bars - Microcomposites (MMFX) - Epoxy Coated Steel (ECS) Clark County Bridge, Kentucky - 2002 Stress/Strain Curves of Various Rebars 300 250 CFRP Rebar 200 Stress (ksi) 150 MMFX Steel 100 ECS Steel Stainless Steel Clad 50 GFRP Rebar Strain (in/in) Clark County Bridge 0 0.0E+00 1.0E-02 2.0E-02 3.0E-02 4.0E-02 5.0E-02 6.0E-02 7.0E-02 Glass FRP Rebars Second Bridge in the US With GFRP Bars Roger’s Creek Deck, Kentucky - 1997

Scott County Bridge, KY FRP & Concrete Piles MMFX and Stainless Steel Clad Bars in Deck US NAVY Platform Panama City, Florida SSC MMFX FRP & Concrete Piles First Deployment of MMFX Steel Bars in the World First Deployment of Stainless Steel Clad Bars in the US FRP & Concrete Piles Acoustic test pool 359 ft by 258 ft, FRP Piles 40 ft deep (magnetically clean)

Diversified Fabricators, Inc. Hardcore Composites End View Bridge Decks - FRP Deck - Aluminum Deck DFI 4 #5 GFRP bars @ ~ 3 in. o.c. Pultruded panels Infrastructure Composites International ICI - CCTI FRP Bridge Decks First Salem Bridge Dayton, Ohio Glass FRP Bars Creative Pultrusions (CP) Placement of FRP Deck Concrete Glass FRP Tubes

Aluminum Deck Placement Deck Connection to Steel Girders Aluminum Bridge Decks KY 974 Bridge Over Howard Creek Aluminum Deck Placement Clark County, KY KY 974 Bridge Over Howard Creek Aluminum Bridge Deck Clark County, KY Fabricated in Holland KY 974 Bridge Over Howard Creek Asphalt Topping Clark County, KY Bridge Ready for Traffic After 2 Hours

CFRP Fabric vs. Steel w CFRP = 0.0051 lb/ft w Steel = 0.19 lb/ft ≈ 37 w CFRP  CFRP Fabric h CFRP = 0.0066” h Steel = 0.056” ≈ 8.5 h CFRP 1” KY 270 Bridge 1” Webster County, KY Ultimate Load = 3.25 kip Aluminum Deck Placement Beam Strengthening 45 o S TRENGTHENING KY 270 Bridge WITH CFRP C LOTH/ F ABRIC Webster County, KY July 30, 2009 CFRP Fabric Test Specimens Bridge Retrofit - Carbon FRP Fabric - High Strength Steel Fabric (Hardwire) - Carbon FRP Laminates

Step 2: Original Solution Crack Injection and Filling of Voids Replace the Superstructure - Cost: ~ $600,000 - Close Bridge to Traffic Step 3: Bridge on KY 3297 over Little Sandy River Alternate Solution Carter County, Kentucky Apply Primer Use CFRP Fabric - Cost: $105,000 (Design, Repair, and 3-yrs Monitoring) - Bridge Remains Open to Traffic (Except for Heavy Trucks) Shear Cracks in P/C Box Beams Step 4: Step 1: Apply Carbon Surface Fabric Preparation Severe Shear Cracks Cracks Growing at an Alarming Rate