Inspection of Steel Girder Bridges
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1 Course Outline Inspection of Steel Girder Bridges Bridge superstructure systems Defects in steel members Failure mechanics Fatigue Constrained Induced fracture (CIF) Inspection Inspection of Pin & Hanger 1 Bridge Superstructure Systems Bridge Superstructure Systems 1. Rolled beams Manufactured from one piece of steel Webs are stocky, therefore no intermediate stiffeners. Used as simple spans with span length from 9 to 15 m Rolled Beam 2. Rolled beams with cover plates Cover plates were added to increase the capacity Cover plates were welded or riveted to the flanges Welded cover plates created fatigue prone detail 2 3 1
2 Bridge Superstructure Systems Bridge Superstructure Systems Rolled Beam with Cover Plates 3. Built up Girders Similar in appearance as rolled beams Custom fabricated, not produced in rolling mills Fabricated from thin plates, hence require stiffeners Older built up girders were riveted, the new are welded plates Continuous girders can have spans over 150 m 4 5 Bridge Superstructure Systems Bridge Superstructure Systems Built-up Girders 4. Girders with Pin and Hanger Analysis is simplified for a hinged structure It moves drainage away from piers Only one pin is required for rotation For translation and rotation, two pins and hanger are provided 5. Steel Arches Three types of arches: deck, through and tied Arch spans range from 300 to 500 m 6 7 2
3 Bridge Superstructure Systems Bridge Superstructure Systems Girder with Pin & Hanger Steel Arch 8 9 Bridge Superstructure Systems Bridge Superstructure Systems 6. Suspension Bridges 7. Trusses Through Truss Pony Truss Deck Truss Suspension Bridge
4 Bridge Superstructure Systems Bridge Superstructure Systems Through Truss Pony Truss Bridge Superstructure Systems Primary and Secondary Members Deck Truss Primary Members for Bridge Systems 1 to 4 Fabricated girders / Rolled beams Diaphragms for curved girders Pin and hanger Secondary Members for Bridge Systems 1 to 4 Diaphragms
5 Primary and Secondary Members Primary Members for Bridge System 7 Trusses (chords, web members) Floor beams Stringers Secondary Members for Bridge System 7 Bracing Steel Damage and Deterioration Corrosion Environmental corrosion Stray current corrosion Stress corrosion Cracking Fatigue Impact Excessive loading Steel Damage and Deterioration Steel Damage and Deterioration Deformation Excessive loading Heat damage Impact Corrosion
6 Steel Damage and Deterioration Steel Damage and Deterioration Corrosion Fatigue Crack Steel Damage and Deterioration Steel Damage and Deterioration Impact Damage Impact Damage
7 Steel Damage and Deterioration Steel Damage and Deterioration Fire Damage Fire Damage Steel Damage and Deterioration Fatigue & Fracture in Steel Members Fatigue Tendency of a member to fail at a stress level below its yield stress when subjected to repeated loading Overload Damage Fracture Critical Member (FCM) Member is in tension Member is non redundant, its failure causes partial or total collapse of a structure
8 Failure Mechanics Types of Fractures in Steel Members Describing the process by which a member fails when subjected to fatigue. Brittle Fracture Ductile Fracture Fatigue Failure Process Fatigue failure process consists of three stages: 1. Crack initiation 2. Crack propagation 3. Fracture Fatigue Crack Categories Details and defects Out of plane distortion
9 Factors Affecting Fatigue Crack Initiation (Details& Defects) 1. Plug welds 2. Tack welds 3. Material flaws External flaws (Surface scabs) Internal flaws (Non metallic inclusions, Rolled in plate defects) 4. Weld flaws Non visible flaws (IP welds, Porosity, Slag inclusions) Visible flaws (Undercut, Overlap) Factors Affecting Fatigue Crack Initiation (Details & Defects) 5. Fabrication Flaws Cutting of plates, Holes, Coping 6. Transportation & Erection Flaws Nicks Notches Indentation 7. In Service Flaws Collision damage Improper heat straightening Torched or notched holes Plug Weld Tack Weld
10 Material External Flaw Material Internal Flaw Incomplete Penetration Weld Incomplete Penetration Weld
11 Weld Crack Due to Slag Inclusion Fillet Weld Draws UNDERCUT OVERLAP Improper Web Coping Correct Web Coping Web Cope
12 Torched Hole Torched Damage Factors Affecting Fatigue Crack Initiation (Out of plane Distortion) TOP FLANGE Girder Differential Deflection DECK WEB GAP WEB STIFFENER DIAPHRAGM STIFFENER
13 Girder Web Gap Distortion Girder Web Gap Distortion WEB GAP TOP FLANGE DISTORTION WEB STIFFENER Factors Affecting Fatigue Crack Propagation Stress Range Stress range Number of cycles Types of details Flange cover plates Transverse stiffeners Bolted joints Longitudinal stiffeners Compression - Compression Min. Stress Tension Stress Range Max. Stress Tension + - Min. Stress Stress Range Max. Stress
14 Flange Crack Growth Process Through Crack at a Cover Plate Rolled Beam Cover Plate Weld Crack Propagation Into the Web Crack Growth at Transverse Stiffener Welded to Web Web Stiffener
15 Constrained Induced Fracture (CIF) Constrained Induced Fracture (CIF) Fracture is not due to fatigue or number of cycles Occurs suddenly with no prior signs Fractures are at intersecting welds or at small gaps between intersecting welds Girder fracture at Hoan bridge Milwaukee was due to CIF STIFFENER GUSSET GIRDER Constrained Induced Fracture (CIF) Constrained Induced Fracture (CIF) Web Fracture
16 Constrained Induced Fracture (CIF) Inspection Procedures & Locations Transverse Stiffener Longitudinal Stiffener Procedures Visual Hands on inspection Physical Removal of dirt, paint etc Identification Fatigue crack may be identified by the development of rust stains Advanced Inspection Techniques Web Inspection Procedures & Locations Corroded Shear Zone & Diaphragm Locations Bearing areas Shear zones Flexure zones Fatigue prone details Out of plane distortion Constrained induced fracture detail Secondary members Areas that trap water and debris Areas exposed to traffic
17 What to do if a Crack is Detected? Determine significance of crack on load carrying capacity Evaluate cause of cracking Show sketches with details of size and location Drill hole at the tip to arrest the growth Check with dye penetrant Take good photographs showing all the details Inspection of Pin & Hanger Note: Cracks perpendicular to primary stresses are very serious Cracks parallel to primary stresses are less serious Pin Location Pin Detail Shear Plates HINGE 45' 70' F.S. ABUT. #1 PIER #1 PIER #2 90' 90' HINGE 70' 90' ABUT. #2 Girder Girder Shear Plates Pin Bottom Flange Web
18 Design Stresses in Pin Actual Stresses in Pin Nut Pin High Stress in Pin Due to Corrosion High Stress in Pin Due to Corrosion Pin Corrosion
19 Hanger Location Hanger Details ABUT. #1 91' PIER #1 HANGER HANGER PIER #2 170' 114' ABUT. #2 ANCHOR SPAN SUSPENDED SPAN ANCHOR SPAN Suspended span Anchor span Stresses in Hanger Actual Tension Moment Actual Tension Deterioration of Pin & Hanger Pin Frozen Corroded Cracks in welded shear plates Hanger Twisted or bent Ceased Cracks in edges
20 Inspection of Pins Pin Measurements Procedure Determine if pins are functioning Visual inspection not very effective Ultrasonic inspection is required Remove nuts if possible Bottom flange elev. alignment Bottom flange gap Preparation for Inspection Removal of Nuts
21 U/T Inspection Inspection of Hangers Procedure Report any corrosion Hanger plate is as critical as pin. Examine edges Check hangers for bowing, out of plane bending Measurements in Pin & Hanger 2 END Suspended span
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