Structures Program. Program Manager: Issam Harik. Structures Program Projects 1996 Present

Transcription

1 CE 120 Introduction to Civil Engineering Wednesday, February 5, 2014 Lexington, KY High Performance Materials for Bridge Strengthening by The Others and Issam Harik Kentucky Transportation Center University of Kentucky Structures Program Program Manager: Issam Harik THE BRENT-SPENCE BRIDGE Department of Civil Engineering Kentucky Transportation Center University of Kentucky Outline - Introduction - High Performance Materials - Conclusions - Acknowledgment Structures Program Projects 1996 Present Field Testing and Modeling Seismic Evaluation Vessel Impact on Bridges Remote Sensing Hazard Mitigation High Performance Materials Homeland Security Outline - Introduction - High Performance Materials - Conclusions - Acknowledgment Sample Bridges US 51 Bridge Over the Ohio River Wickliffe, KY to Cairo, IL

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

3 -0.4 FE Modeling and Calibration Allen County Bridge Mode Shape Magnitude Plan FEM Field Testing Bridge Longitudinal Distance 1 st Vertical Mode 3-D View Elevation Monitoring Locations Mode Shape Magnitude FE Modeling and Calibration Plan 1.2 FEM 1 Field Testing Bridge longitudinal Distance 3-D View 1 st Transverse Mode (+Torsion) Elevation Allen County Bridge Allen County Bridge North Pressure Pier # dia. conduit thick, #10 crushed stone Plan View Elevation View Instrumentation under Spread Footing Remote Monitoring and Intelligent Sensing Allen County Bridge Pressure Cell Layout

4 Eastbound I-64 Possible Instrumentation Plan Eastbound US60 Westbound US60 (To Versailles) (To Frankfort) North Outline Crack Sensor Strain gage (Span 3) Westbound I-64 (To Louisville) Camera #1 Strain gage Crack sensor (Span 1) Note: Depending on additional cost, instrumentation on Span 1 may not be placed - Introduction - High Performance Materials - Conclusions - Acknowledgment Eastbound I-64 (To Lexington) Vehicle Height Sensor Impact Detector Camera #2 I-64 Parallel Bridges over US60 High Performance Materials SPAN 1 SPAN 2 (Towards Lexington) SPAN 3 Westbound US60 FRP Components (FRP = Fiber Reinforced Polymer) (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 Eastbound US60 (Towards Versailles) BARGE IMPACT ON BRIDGES I-64 Parallel Bridges over US60 Eastbound US 60 Westbound US 60 North Instrumentation Plan - US 41N Bridge FRP COMPOSITES (To Versailles) (To Frankfort) 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. KY Location of Instrumentation Westbound I-64 (To Louisville) IN Eastbound I-64 (To Lexington) Pier B Pier C Pier D 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

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

6 FRP BARS (Thermosetting Polymers) FRP BARS (Thermoplastics)

7 FRP APPLICATIONS 2011 Ducati Diavel Carbon Audi Carbon Skis 2007 Full Carbon Fiber Road Racing Bike Dura ACE King Cobra Carbon CB Iron set Golf Club

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

9 Sea Shadow Stealth Boat All Carbon Fiber M-14/M1A Rifle Bridge Design Parameters 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" Walther P22 Carbon Fiber Frame 3.4" 22LR W18x46 Section 2 Girders Required E = 29,000 ksi ~ 200 GPa 18" 6 ~ 153mm 18 ~ 460mm GFRP Beam Requirements 6ft ~ 2m Ghost Supercavitating Ship for the Navy THE CLEARCREEK BRIDGE PULTRUDED HYBRID CARBON/GLASS FRP I-BEAMS 30 GFRP Girders required using 18" (~460mm) deep sections E = 2500 ksi ~ 17 GPa (1/12 E steel )

10 GFRP Beam Requirements Bridge Fabrication Bridge Construction 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

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

12 - Longest FRP Girder Bridge - First application of Inverted Cable Stay - First Hybrid FRP Bridge THE SWINGING BRIDGE PULTRUDED GFRP DECK Johnson County, KY

13 Rebars - Fiber Reinforced Polymer (FRP) - Stainless Steel Clad (SS) - Microcomposites (MMFX) - Epoxy Coated Steel (ECS) First Bridge in the US With CFRP Bars Clark County Bridge, Kentucky Stress/Strain Curves of Various Rebars CFRP Rebar 200 Stress (ksi) 150 MMFX Steel 100 ECS Steel Stainless Steel Clad 50 GFRP Rebar 0 Strain (in/in) 0.0E E E E E E E E-02 Clark County Bridge Glass FRP Rebars Second Bridge in the US With GFRP Bars Roger s Creek Deck, Kentucky

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

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

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

17 CFRP Fabric vs. Steel w CFRP = lb/ft w Steel = 0.19 lb/ft 37 w CFRP CFRP Fabric h CFRP = h Steel = KY 270 Bridge Webster County, KY 1 1 Ultimate Load = 3.25 kip 8.5 h CFRP Aluminum Deck Placement Beam Strengthening 45 o KY 270 Bridge Webster County, KY July 30, 2009 STRENGTHENING WITH CFRP CLOTH/FABRIC Bridge Retrofit - Carbon FRP Fabric - High Strength Steel Fabric (Hardwire) - Carbon FRP Laminates CFRP Fabric Test Specimens

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

19 Crack Monitor on Inside Beam Face The State Journal, December, 2001 Step 5: CFRP Fabric on Outside Face Painted to Match Concrete Color No Crack Movement has Occurred Since Repair Was Completed in October 2001 Bridge Monitoring (10/01 to 12/06) Scaffolding Used for Monthly Bridge Monitoring Conclusion - Cost Effective: $105,000 for Repair vs. $600,000 for Replacement - Repair is Effective: No Crack Movement Since Repair was Completed in October No Traffic Control or Disruption The Daily Independent November, 2001 CFRP Fabric on Inside Faces of the Beams Was Not Painted to Match Concrete Color Associated Press November, 2001 I-65 North-South Expressway, Jefferson County KENTUCKY, USA Crack Monitor

20 I-65 Elevated Expressway I-65 Elevated Expressway Louisville, KY Instrumentation on Span 117 (Pier 8) on Southbound I-65 Expressway BEAM 6 Cracks at piers with fixed restraints. LVDT 5 (V) BEAM 7 LVDT 1 (H) Exp. Fix Fix Bridge deck Exp. PC girders LVDT 3 (H) THERMOMETER AND DATA ACQUISITION SYSTEM LVDT 2 (V) Retrofit Locations PIER 6 at Main & Hancock ST Steel rebars PC girder LVDT 3 (H) As of May 1, 2004 Relative Horizontal Movement (x 10-3 in) 80 LVDT Crack is closing Elapsed Time (Hours) PIER I-65 over Muhammad Ali Blvd. PIER 4 at Jefferson & Preston ST Crack Beam 7 Span Pier cap Temperature ( o F) PC spans between Jacob & Gray ST Embedment length of steel rebars PC spans between Broadway & Chestnut Elapsed Time (Hours) Retrofit Locations Cracks in prestressed concrete girders near supports LVDT 2 (V) as of May 1, 2004: Relative Vertical Movement (x 10-3 in) 80 LVDT PC beam moving downward relative 30 to pier cap Elapsed Time (Hours) Beam 6 Span Temperature ( o F) PC spans between Jacob & Gray ST Elapsed Time (Hours)

21 Elapsed time (Hr) LVDT Elapsed time (Hr) LVDT Elapsed time (Hr) Elapsed time (Hr) LVDT Elapsed time (Hr) Elapsed time (Hr) LVDT Elapsed time (Hr) Elapsed time (Hr) Rel. Ver. Move. (x10-3 in) Temperature ( o F) Vertical Movement Before the Repair After the Repair Beam LVDT 6 2 2/11/200 4 PC beam moving downward relative to pier cap Rel. Ver. Move. (x10-3 in) 2/14/200 9/4/ Period during which design and construction of retrofit took place Temperature ( o F) 10/31/20 06 First Application of Triaxial Fabric on Bridges Repair at Pier (I-65 over Muhammad Ali Blvd.) Transportation Research Board Annual Meeting January 13-17, 2013 Bridge Retrofit Using Tri-axial CFRP Fabric in Simpson County, KY PIER I-65 over Muhammad Ali Blvd. Horizontal Movement Tri-axial CFRP Fabric Application Before the Repair After the Repair Beam 6 LVDT 1 Rel. Hor. Move. (x10-3 in) Temperature ( o F) 2/11/20 04 Crack is closing Rel. Hor. Move. (x10-3 in) 2/14/20 9/4/ Period during 6 which design and construction of retrofit took place Temperature ( o F) 10/31/2 006 Repair Using Triaxial CFRP Fabric

22 Repair Completed Retrofit Measures: Hardwire Steel FRP Strengthening With CFRP Laminates Repair Completed Testing of Beam Strengthened With CFRP Laminates Testing of Beam Strengthened With CFRP Laminates Second Bridge in the US With Steel Wire Fabric High Strength Steel Fabric (Hardwire)

23 P 3 P 4 P 5 P 6 P 7 Number of CFRP Laminates Required for Flexural Strengthening S 4 S 5 S 6 S 7 G 1 LOUISA (KY) G 2 G 3 G 4 G 5 G 6 1-Strip 2-Strips 2-Strips FORT GAY 1-Strip 2-Strips 2-Strips (WV) 3-Strips 2-Strips 4-Strips 3-Strips 2-Strips 4-Strips 2-Strips 2-Strips 4-Strips Louisa-Fort Gay Bridge Over the Tug Fork and Big Sandy Rivers G 7 G 8 G 9 G 10 Tishkovka Bridge Perm, Russia Louisa-Fort Gay Bridge Over the Tug Fork and Big Sandy Rivers Coal Truck Weigh in Motion Data: 225,000 lb (100 Metric Ton) Application of CFRP Laminates to Span 4 Need to Increase Strength of Girder 1 and Girder 5 by 15% 3-Laminates 1-Laminate 1 st T-girder 25k 50k 50k 50k 50k 2-Laminates 5 th T-girder Flexural Cracks in RC Spans Louisa-Fort Gay Bridge RC Girder Flexural Cracks Technology Exchange with Perm, Russia Tishkovka Bridge Perm, Russia Diaphragms

24 Firsts in the Eastern Block Countries - Production of CFRP Laminates Introduction Ultra High Modulus CFRP Plates (Modulus 450 GPa /65250 ksi) - Retrofit Design With CFRP Laminates - Bridge Retrofitted With CFRP Laminates Takiguchi Bridge, 2008 (Tokyo, Japan) Retrofit of the KY 32 Bridge in Scott County, KY Steel Girders Strengthened With Ultra High Modulus CFRP Laminates Ultra High Modulus CFRP Laminate KY 32 Bridge CFRP Laminate with peel ply Epoxy High Modulus CFRP Laminates KY 32 Bridge Ultra High Modulus: E CFRP > 2E Steel [or E CFRP > 400 GPa (58000 ksi)] High Modulus: E Steel [or 200 GPa ] < E CFRP <2E Steel [or 400 GPa ] E Steel [or ksi] < E CFRP <2E Steel [or ksi] mm ( ) thick ultra high modulus CFRP plate Intermediate Modulus: 0.5E Steel [or 100 GPa] < E CFRP < E Steel [or 200 GPa] mm ( ) thick ultra high modulus CFRP plate 0.5E Steel [or ksi] < E CFRP < E Steel [or ksi] Low Modulus: E CFRP < 0.5E Steel [or 100 GPa (14500 ksi)] All dimensions are in millimeters

25 Limitations of Current Retrofit Methods Lexington Herald Leader April 22, 2010 Second Bridge in the World With UHM CFRP Laminates State Highway 92 Bridge, Pottawattamie County, Iowa

26 CatStrong CFRP Rod Panels Developed at U. of KY KY32 Bridge over Lytles Creek in Scott County Louisa-Fort Gay Bridge 60 ft 58.3 ft 90 ft Louisa-Fort Gay Bridge US150 Bridge, Washington County, KY 6 CFRP rods Fiberglass mesh backing 6 12 Louisa-Fort Gay Bridge 48

27 Designation CRP-195 vs. CFRP Fabric CRP 195 Strength = 195,700 lbs/ft t C =0.156 in WC = 0.43 lb/ft (without epoxy) W F = lb/ft 0.3 W CRP (without epoxy) t F =0.16 in (with epoxy) Type 1 Truck W = 40,000 lbs 1 ft 1 ft Type 3 Truck W = 73,500 lbs Ultimate Load = 195 kip Type 4 Truck W = 80,000 lbs CatStrong CRP-195 vs. CFRP Laminate s Epoxy t Concrete Carbon panel placement Diameter, d Rod area Rod Spacing, s (in) (x10-3 in 2 ) (in) d CFRP rod Bars per panel Weight (lb./panel) Strength (kip/ft.) W C = 0.43 lb/ft (without epoxy) t C =0.156 in 1 ft W L= 0.35 lb/ft (without epoxy for 2.6 laminates) t L=0.047 in 4 in 4 in 2.4 in CatStrong Field Applications CRP CRP Ultimate Load = 195 kip CRP CRP CRP CRP-195 vs. Steel CRP-195 vs. HARDWIRE Repair of the KY218 Bridge Over Blue Springs Creek, Hart County, KY First Application of CatSrong CRP80 (week of September 19, 2011) WC = 0.43 lb/ft W S = lb/ft 26 W C WC = 0.43 lb/ft (without epoxy) W H = 1.43 lb/ft 3.3 W CRP (without epoxy) t C=0.156 in t S = 0.28 in t C =0.156 in t H =0.141 in Step 1: Application of resin on concrete girder Step 2: Application of CRP80 on resin 1.0 ft 1.0 ft 1 ft 1 ft Ultimate Load = 195 kip Ultimate Load = 195 kip Step 3: Application of resin coat on CRP80 Girder strengthened with CRP80

28 Retrofit of Impacted Girder on the Sunnyside-Gotts Road over I-65 Caldwell Road over Blue Grass Parkway Caldwell Road over Blue Grass Parkway Impacted Girder Impacted Girder

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

30 Day 6 (Dawn of Day 7): Retrofitted Zone Retrofitted Girder Stronger Than Original Girder Beam Brought Back to Original Shape (8/10/12) Beam After Repair (9/18/12) (Repaired beam is stronger than the original beam when the bridge was first opened to traffic) KY 81 Bridge, McLean County, KY Outline Application of CatStrong (9/17/12) - Introduction - Space Age Material - Conclusions - Acknowledgment Removal of Loose Concrete, Rust From Steel, etc. (8/9/12) Application of CFRP Fabric (9/18/12) Conclusion - HP Materials are now viable alternative construction material - Structural repair is an area where HP Materials - Health Monitoring

31 Outline - Introduction - High Performance Materials - Conclusions - Acknowledgment Thank You and Have a Nice Day 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?