ce 120 – introduction to civil engineering wednesday ...rsouley/ce 120/9/harik - presentation ce...
TRANSCRIPT
High Performance Materials for Bridge
Strengthening
Department of Civil EngineeringUniversity of KentuckyKentucky Transportation Center
CE 120 – Introduction to Civil Engineering Wednesday, February 5, 2014Lexington, 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 CenterUniversity 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
Henderson, KY to Evansville, IN
Owensboro Bridge
The Maysville Bridge
Field Testing
3-D Accelerometers
Field Testing
Field Testing
Field Testing
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
1.2
0 500 1000 1500 2000
FEM
Field Testing
Mo
de S
hap
e M
agn
itud
e
Bridge Longitudinal Distance
3-D View
Plan
1st Vertical ModeElevation
FE Modeling and Calibration
3-D View
Plan
1st Transverse Mode (+Torsion) Elevation
-0.2
0
0.2
0.4
0.6
0.8
1
1.2
-100 0 100 200 300 400 500 600 700
FEMField Testing
Mod
e S
hap
e M
ag
nitu
de
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 #112’-0”
0’-6”6’-0”
12’-0”
7
1
6
54
3
2
6’-0”
Allen County Bridge
Plan View Elevation View
Instrumentation under Spread Footing
Allen County Bridge
Pressure Cell Layout
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 2SPAN 1SPAN 3
NorthEastbound 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 SensorStrain gage(Span 3)
Camera #1
Camera #2
Vehicle Height SensorImpact Detector
Note: Depending on additional cost, instrumentation on Span 1 may not be placed
BARGE IMPACT ON BRIDGES
Pier BPier C Pier D
KY
IN
Instrumentation Plan - US 41N BridgeInstrumentation 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
Glass FRP Bar
FRP Composite Materials
Reinforcements Fillers AdditivesResins
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
FRP BARS(Thermosetting Polymers)
FRP BARS(Thermoplastics)
FRPAPPLICATIONS
2007 Full Carbon FiberRoad Racing Bike Dura ACE
2011 Ducati Diavel Carbon
Audi CarbonSkis
King Cobra CarbonCB Iron set Golf Club
Total Carbon Element Tennis Racket (TB016)
Boats
F-117 Nighthawk
Stealth Bomber
Stiletto Stealth Ship
Sea Shadow Stealth Boat
Sea Shadow Stealth Boat
Stealth Submarine
GhostSupercavitating Ship for the Navy
All Carbon FiberM-14/M1A Rifle
Walther P22 Carbon FiberFrame 3.4" 22LR
THE CLEAR CREEK BRIDGEPULTRUDED 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 Section2 Girders Required
E = 29,000 ksi ~ 200 GPa
60ft ~ 20m
6ft ~ 2m
6” ~ 153mm18“ ~ 460mm
GFRP Beam Requirements
30 GFRP Girders required using 18" (~460mm) deep sections
E = 2500 ksi ~ 17 GPa (1/12 Esteel)
6ft ~ 2m
GFRP Beam Requirements
6ft ~ 2m
8 Girders required using 24" (~ 610mm) sections
E = 2500 ksi ~ 17 GPa (1/12 Esteel)
Carbon andGlass Fibers
Laboratory Testing
Bridge Fabrication
Bridge Assembly
Bridge Construction
Bridge Construction
Bridge Construction
Bridge Construction
Bridge Construction
Bridge Construction
Bridge Construction
GFRP Cables
Bridge Construction
Bridge Construction
Opening CeremonyNovember 14,1996
Clear Creek Bridge, Kentucky
Load Test
Bridge Visit By International Researchers
Bridge Visit By Japanese Researchers
- Longest FRP Girder Bridge
- First Hybrid FRP Bridge
- First application of Inverted Cable Stay
THE SWINGING BRIDGE
PULTRUDED GFRP DECK
Johnson County, KY
Rebars- Fiber Reinforced Polymer (FRP) - Stainless Steel Clad (SS)- Microcomposites (MMFX)- Epoxy Coated Steel (ECS)
0
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)
Stre
ss (
ksi)
MMFX Steel
Stainless Steel CladECS 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
MMFXSSC
Scott County Bridge, KYMMFX and Stainless Steel Clad Bars in Deck
First Deployment of MMFX Steel Bars in the World
First Deployment of StainlessSteel Clad Bars in the US
FRP Piles
US NAVY PlatformPanama City, Florida
Acoustic test pool 359 ft by 258 ft,40 ft deep (magnetically clean)
FRP & Concrete Piles
FRP & Concrete Piles
FRP & Concrete Piles
Bridge Decks
- FRP Deck - Aluminum Deck
FRP Bridge Decks
Creative Pultrusions (CP)
Hardcore Composites
Infrastructure Composites International
ICI - CCTI
Glass FRP Bars
Glass FRP TubesConcrete
Diversified Fabricators, Inc.
End View
DFI 4
Pultruded panels
#5 GFRP bars @ ~ 3 in. o.c.
First Salem BridgeDayton, Ohio
Placement of FRP Deck
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 TrafficAfter 2 Hours
Deck Connection to Steel Girders
KY 974 Bridge Over Howard Creek Clark County, KY
Asphalt Topping
KY 270 BridgeWebster County, KY
July 30, 2009
KY 270 BridgeWebster 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
Bridge on KY 3297 over Little Sandy RiverCarter County, Kentucky
Shear Cracks inP/C Box Beams
Cracks Growing at an Alarming Rate
SevereShear
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
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 MovementSince 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
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 ExpresswayLouisville, 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
0
10
20
30
40
50
60
70
80
0 400 800 1200 1600
Elapsed Time (Hours)
Rel
ativ
e H
oriz
onta
l Mov
emen
t (x
10-3 in
)
LVDT 3
0
10
20
30
40
50
60
70
80
90
100
0 400 800 1200 1600
Elapsed Time (Hours)
Tem
pera
ture
(oF
)
Crack is closing
LVDT 3 (H) As of May 1, 2004
Beam 7 Span 117
-10
0
10
20
30
40
50
60
70
80
0 400 800 1200 1600
Elapsed Time (Hours)
Rel
ativ
e V
ertic
al M
ovem
ent (
x 10
-3 in
)
LVDT 2
0
10
20
30
40
50
60
70
80
90
100
0 400 800 1200 1600
Elapsed Time (Hours)
Tem
pera
ture
(oF
)
PC beam moving downward relative to pier cap
LVDT 2 (V) as of May 1, 2004:
Beam 6 Span 117
-80
-60
-40
-20
0
20
40
60
80
100
0 2000 4000 6000 8000 10000
Elapsed time (Hr)
Rel
. Hor
. Mov
e. (
x10 -3
in)
LVDT 1
0
10
20
30
40
50
60
70
80
90
100
0 2000 4000 6000 8000 10000
Elapsed time (Hr)
Tem
pera
ture
(oF
)
Beam 6LVDT 1
2/11/2004
2/14/2005
Crack is closing
-80
-60
-40
-20
0
20
40
60
80
100
0 500 1000 1500 2000
Elapsed time (Hr)
Rel
. Hor
. Mov
e. (
x10 -3
in)
LVDT 1
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000
Elapsed time (Hr)
Tem
pera
ture
(oF
)
9/4/2006Period during
which design and construction of retrofit took place
10/31/2006
Horizontal MovementBefore the Repair After the Repair
Vertical MovementBefore the Repair After the Repair
0
10
20
30
40
50
60
70
80
90
100
0 2000 4000 6000 8000 10000
Elapsed time (Hr)
Tem
pera
ture
(o F)
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000
Elapsed time (Hr)
Tem
pera
ture
(o F)
-10
-8
-6
-4
-2
0
2
4
6
8
10
0 2000 4000 6000 8000 10000
Elapsed time (Hr)
Rel
. Ver
. Mov
e. (x1
0 -3 in
)
LVDT 2
Beam 6LVDT
2
2/11/2004
2/14/2005
PC beam moving downward relative to pier cap
-10
-8
-6
-4
-2
0
2
4
6
8
10
0 500 1000 1500 2000
Elapsed time (Hr)
Rel
. Ver
. Mov
e. (x1
0 -3 in
)
LVDT 2
9/4/2006
10/31/2006
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 TriaxialCFRP 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
Repair Completed
Repair Completed
High Strength Steel Fabric (Hardwire)
Retrofit Measures:Hardwire Steel FRP
Second Bridge in the US With Steel Wire Fabric
Strengthening WithCFRP Laminates
Testing of Beam Strengthened With CFRP Laminates
Testing of Beam Strengthened With CFRP Laminates
Louisa-Fort Gay BridgeOver the Tug Fork and Big Sandy Rivers
Coal Truck Weigh in Motion Data:
225,000 lb (100 Metric Ton)
Louisa-Fort Gay BridgeOver 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-Laminate3-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
- 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)]
IntroductionUltra 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
Lexington Herald LeaderApril 22, 2010
Second Bridgein the WorldWith UHM
CFRP Laminates
Limitations
of Current
Retrofit Methods
State Highway 92 Bridge, Pottawattamie County, Iowa
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
CatStrongCFRP Rod Panels
Developed at U. of KY
CFRP rods
Fiberglass mesh backing
12”
6”6”
48”
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 WCWC = 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 WCRPWC = 0.43 lb/ft
Ultimate Load = 195 kip
(without epoxy)(without epoxy)
(with epoxy)
CRP-195 vs. CFRP Laminate
1 ft4 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 WCRPWC = 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, KYFirst Application of CatSrong CRP80 (week of September 19, 2011)
Step 2: Application ofCRP80 on resin
Step 3: Application of resincoat on CRP80
Girder strengthened withCRP80
Step 1: Application of resinon concrete girder
Caldwell Road over Blue Grass Parkway
Caldwell Road over Blue Grass Parkway
Retrofit of Impacted Girderon the Sunnyside-Gotts Road over I-65
Impacted Girder
Impacted Girder
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
Day 6 (Dawn of Day 7): Retrofitted Zone
Retrofitted Girder Stronger ThanOriginal 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
Outline
- Introduction
- High Performance Materials
- Conclusions
- Acknowledgment
Personnel 1996 – PresentStructures 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 Youand
Have a Nice Day