an overview of composites usage in bridge facilities...

Proceedings of the International Conference and Exhibition on Reinforced Plastics ICERP 2008 February 7-9, 2008, Mumbai, India FRP Institute

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AN OVERVIEW OF COMPOSITES USAGE IN BRIDGE FACILITIES IN THE STATE OF MISSOURI, USA

D. Holdener1, J.J. Myers 2, A. Nanni3

1 Graduate Research Assistant, Center for Infrastructure Engineering Studies, Department of Civil, Architectural &

Environmental Engineering, Univ. of Missouri–Rolla, Rolla, MO, USA 2 Associate Professor, Center for Infrastructure Engineering Studies, Department of Civil, Architectural &

Environmental Engineering, Univ. of Missouri–Rolla, Rolla, MO, USA 3 Lester and Gwen Fisher Endowed Scholar Professor and Chair Department of Civil, Architectural &

Environmental Engineering, Univ. of Miami, Coral Gables, FL, USA ABSTRACT Fiber-reinforced polymer (FRP) technology continues to make strides in both new construction applications and strengthening applications of structurally deficient bridges in the United States primarily due to its corrosion resistance, high strength to weight ratio and in many cases rapid installation processes.

This paper provides an overview of composites usage over the past decade in the State of Missouri, USA. This includes new construction applications including internally reinforced FRP-RC bridges as well as fully composite bridges. Externally strengthening applications of structurally deficient bridges is also discussed using techniques such as manual wet lay-up systems, procured plate and strip systems, near surface mounted (NSM) systems, and mechanically fastened (MF) systems.

Validation of long-term durability performance and the comprehensive development of inspection criteria/guidelines are needed before FRP systems will gain widespread acceptance throughout the engineering and civil infrastructure community. Therefore, many of the Missouri demonstration projects have included on-going monitoring and load testing to validate these systems and demonstrate their long-term durability performance. INTRODUCTION The State of Missouri, USA has had a myriad of FRP projects for both strengthening of existing bridges and new FRP bridge construction. Most of these bridge projects were the result of research conducted at the University of Missouri-Rolla (UMR). This paper will provide an overview of these projects with specific emphasis on individual bridge characteristics, strengthening schemes and recent monitoring results. This paper is broken down as follows. First, the bridges will be compared in tabular form and depicted on a map of Missouri. Second, new bridges constructed with FRP technology will be discussed, while listing facts about the bridges and their FRP construction. Finally , existing bridges strengthened with FRP within the State of Missouri will be presented. BRIDGE OVERVIEW Table 1 provides a number associated with each bridge that corresponds to Figure 1 that depicts each bridge’s relative location within Missouri. Please note that because of brevity concerns not every bridge will be discussed in this paper that is listed in Table 1; however, the appropriate reference has been provided in the table and appendix for each of these bridges for further reading.

Proceedings of the International Conference on Reinforced Plastics 2008

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Table 1. Bridge Overview Summary

No. Bridge ID Bridge Location

Year Built

Year Strengthened

Type of Construction

Composite Material

Used

Retrofit System

Project Type

1 Walker St. Rolla, MO 1999 N/A Precast Concrete Boxes

GFRP Bars N/A N [1]

2 Pedestrian UMR Campus 2000 N/A FRP Square Tubes GFRP & CFRP Tubes N/A N [2]

3 St Johns St . St James Mo 2000 N/A FRP Deck & Steel Girders

GFRP Panels N/A N [3]

4 Jay St. St James Mo 2000 N/A FRP Deck & Steel Girders

GFRP Panels N/A N [3]

5 St Francis St. St James Mo 2000 N/A FRP Panels GFRP Panels N/A N [3]

6 Walters St. St James Mo 2001 N/A FRP-RC Panels GFRP & CFRP Bars

N/A N [3]

7 Southview Dr. Rolla, MO 2004 N/A FRP RC deck GFRP Bars

& Prest. CFRP

N/A N [4]

8 G-270 Iron Co. 1922 1999 Concrete Slab CFRP S R [5] 9 J-857 Phelps Co. 1932 1999 Concrete Slab CFRP RD & S R [6]

10 A-10062 St. Louis Co. U.A. 2000 Damaged Prest. Girder CFRP Patch &

S R [7]

11 A-4845 Jackson Co. U.A. 2000 Damaged Prest. Girder CFRP S R [8]

12 A-5657 Pulaski Co. U.A. 2002 Damaged Prest. Girder

CFRP S R [9]

13 W 7th St Fulton, MO 1910s 2002 RC Open Spandrel Arch

CFRP S R [10]

14 Brown School Boone Co. U.A. 2002 Precast RC Channels

CFRP S R [11]

15 Coats Lane Boone Co. U.A. 2002 Precast RC Channels CFRP S R [11]

16 Creasy Spring Boone Co. U.A. 2002 Precast RC Channels CFRP S R [11]

17 Martin Spring Phelps Co. 1926 2002 Concrete Slab CFRP RD & S R [12] 18 P-962 Dallas Co 1956 2003 D.T. CFRP, SRP RD & S R [13] 19 T-530 Crawford Co 1939 2003 D.T. CFRP S R [13] 20 X-596 Morgan Co 1946 2003 D.T. CFRP RD & S R [13] 21 X-495 Iron Co 1948 2003 D.T. CFRP RD & S R [13]

22 Y-298 Pulaski Co 1937 2003 Concrete Slab P.C. MFS & S R [13]

23 1330005 Phelps Co. U.A. 2004 D.T. P.C. MFS R [14] 24 3855006 Phelps Co. U.A. 2004 D.T. P.C. MFS R [14] 25 2210010 Phelps Co. U.A. 2004 Concrete Slab P.C. MFS R [14]

26 1480230 Green Co. 1933 2005 GFRP Grid Deck GFRP GFRP SIP form

R [15]

Key:

U.A. – Information Unavailable N/A –Not Applicable D.T. – Deck Girder & Reinforced Concrete T-Beam P.C. – Pre-cured Mechanically Fastened CFRP MFS – Mechanically Fastened Strips

S – Sheets RD – Rods SRP – Steel Reinforced Polymer N- New Construction R – Repair / Retrofit Construction


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NEW BRIDGE CONSTRUCTION WITH FRP Walker Street Bridge Walker Bridge is located in the City of Rolla, Missouri and replaced three corrugated steel pipes encased in concrete. The new bridge utilizes two precast box sections with FRP internal reinforcing bars. The dimensions of the boxes are 4 ft. 11 in. (1.5 m) square with a 6 in. (152 mm) wall thickness. The bridge was load tested in 2000 utilizing a loaded truck with predetermined stops and deflections were recorded at midspan utilizing linear variable differential transformers (LVDT) [1]. UMR Pedestrian Bridge The composite pedestrian bridge installed on the UMR campus was the first FRP bridge composed entirely of composites built in Missouri. This bridge is comprised of seven layers of 3 in. (76 mm) pultruded composite tubes. The top and bottom layers are CFRP tubes for increased strength whereas the middle layers of tubes are GFRP in order to limit cost. The total length of the bridge is 30 ft. (9.14 m) and 9 ft. (2.74 m) in width; the bridge was designed for an AASHTO H20 load rating [2].

Figure 1: Location of FRP bridges in Missouri, USA.


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St James Bridges St. Francis Street Bridge St. Francis Street Bridge was constructed utilizing glass FRP honeycomb sandwich panels exclusively. Four panels were utilized with a depth of 23.6 in. (600 mm) including a 0.375 in. (9.5 mm) polymer concrete wearing surface [3]. The bridge span length is 26.25 ft (8.00 m) with a width of 27.33 ft (8.33 m). Four stacked GFRP tubes were used within the joint to transfer load between panels. Figure 2 shows a current picture of the bridge.

St. Johns and Jay Street Bridges St. Johns and Jay Street Bridges were constructed utilizing glass FRP honeycomb sandwich panels for the deck supported by steel girders. The primary difference between the two bridges lies in the fact that St. Johns Street Bridge has six lateral panels whereas Jay Street Bridge is comprised of four longitudinal panels. The panel and bridge dimensions are provided in Table 2 [3].

Table 2. St. Johns Street and Jay Street Bridges Properties [3]

Bridge Panel

Thickness Girder Size # of

Girders Span

Length Bridge Width

St. Johns Street

5.125 in (130.2 mm) W14 X 90 7

26.5 ft (8.08 m)

25.5 ft (7.77 m)

Jay Street 6.625 in

(168.3 mm) W14 X 91 7

27.0 ft (8.23 m)

25.5 ft (7.77 m)

The panels are mechanically clamped to the girders through the use of a GFRP tube that fits between adjacent panels [3]. This fastener is utilized in eight locations for the St. Johns Street Bridge and nine locations for the Jay Street Bridge. Figure 3 shows St. Johns Street Bridge during load testing. Walters Street Bridge Walters Street Bridge was constructed utilizing precast concrete panels with FRP bars. Nine panels were utilized with a depth of 1 ft (0.30 m) and a width of 2.83 ft (0.86 m) [3]. The bridge span length is 24 ft (7.32 m) with a width of 25.5 ft (7.77 m). Load transfer at the panel joints is accomplished by embedded angles that were welded together onsite. The joint was later filled with grout to seal the connection. Figure 4 shows a current picture of Walters Street Bridge.

Figure 3: St. Johns Street Bridge.

Figure 2: St. Francis Street Bridge.

Proceedings of the International Conference and Exhibition on Reinforced Plastics ICERP 2008 February 7-9, 2008, Mumbai, India FRP Institute

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EXISTING BRIDGES STRENGTHENED WITH FRP Bridge G-270 Bridge G-270 is located on Route 32 in Iron County Missouri. It is a single 20 ft. (6.10 m) span and is a solid reinforced concrete slab (See Figure 5). Strengthening consisted of eight sheets of CFRP 20 in. (508 mm) in width; two of these strips were used for destructive testing. Deflection measurements were taken in 1999 before and after strengthening using LVDTs at quarter points on the bridge [5]. Bridge J-857 Bridge J-857 is located on Route 72 south of Rolla, MO. This bridge consists of three spans: one was strengthened with CFRP surface bonded strips, another was strengthened with NSM CFRP bars and the third deck was used as a control specimen. The columns of the bridge were also strengthened with NSM CFRP bars and jacketed with CFRP and GFRP strips. The bridge underwent extensive non-destructive testing followed by destructive testing of the bridge [6]. Damaged Prestressed Concrete Girder Bridges Bridges A-10062, A-4845, and A-5657 are all prestressed concrete girders that were damaged and subsequently strengthened with CFRP. The strengthening consisted of FRP sheets applied via manual lay-up to the soffit of these girders. FRP U-wraps were then applied around the flexural strengthening to prevent delamination [7-9]. Martin Spring Bridge Martin Spring Bridge is located on Martin Spring outer road in Phelps County, Missouri. This bridge was originally constructed in 1926 and consists of a three-span simply supported reinforced concrete slab; each slab is 22 ft. (6.71 m) long and 14 in. (356 mm) thick. The bridge was strengthened in 2004 utilizing manual FRP lay-up on all three spans and NSM bars on span 2. Deflection measurements were taken before and after strengthening using LVDTs primarily located at the midspan location [12].

Figure 4: Walters Street Bridge.

Figure 5: Bridge G-270


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MF-CFRP Bridges Bridges 133005, 3855006, and 2210010 are all bridges located within Phelps County, Missouri that have been strengthened utilizing MF-CFRP. These bridges all have relatively short spans between 32 and 25 feet (9.75 and 7.62 m) [14]. The CFRP strips were attached with bolts which required minimal time with little substrate preparation; however, the long-term performance of this strengthening technique is not yet documented. The Five Bridge Project The Five Bridge project has structural monitoring in the form of load testing that is on going. Each of these bridges has undergone load testing biannually since 2003 and will continue through 2008. Bridge X-596 Bridge X-596 is located on Hwy C and spans Lander’s Fork Creek in Morgan County, Missouri. This bridge consists of three simply supported reinforced concrete spans of lengths 42.5, 52.5, and 42.5 feet (13.0, 16.0 and 13.0 m) respectively with a roadway width of 20 feet (6.1 m). The bridge is shown in Figures 6 and 7 before strengthening. The 6 in. (152 mm) deck is supported by three tee beams spaced 9 ft. (2.74 m.) centers [13]. X-596 was strengthened using NSM bars for flexure and FRP manual lay-up for flexure and shear. In order to accomplish the installation of these composites, 116 ft3 (0.566 m3) of deteriorating concrete needed to be removed and the new surface cleaned [13].

Figure 6: Bridge X-596 [13]

Figure 7: Bridge X-596 substructure [13]

Bridge T-530 Bridge T-530 is located on Hwy M and spans Crooked Creek in Crawford County, Missouri. This bridge consists of five simply supported spans all 47 ft. (14.3 m) long with a roadway width of 23 ft. (7.01m). The 6 in. (152 mm.) deck is supported by four tee beams spaced 6.5 ft. (1.98 m) on center. The bridge is shown in Figures 8 and 9 before strengthening [13]. T-530 was strengthened in flexure using both manual lay-up and precured laminates on the deck and girders. 10 ft3 (0.283 m3) of concrete needed to be removed from deteriorated areas and the surfaces were then prepared and the reinforcement was placed.

Figure 8: Bridge T-530 [13] Figure 9: Bridge T-530 substructure [13]

Exposed Rebar


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Bridge X-495 Bridge X-495 is located on Hwy C and spans Crane Pond Creek in Iron County, Missouri. This bridge consists of three simply supported spans of lengths 42.5, 52.5, and 42.5 ft. (13.0, 16.0, and 13.0 m) respectively with a deck width of 24 ft. (7.32 m). The load testing was conducted on the center of the middle span. The 6 in. (152 mm.) deck is supported by three tee beams spaced 9 ft. (2.74 m.) on center [13]. Figs. 10 and 11 illustrate the visual details of the bridge prior to strengthening. X-495 was strengthened in flexure using NSM bars and manual FRP lay-up. Due to the good condition of this bridge, concrete repair work did not require the removal of deteriorated concrete. The surface was prepared in accordance with accepted practice for installation of FRP via manual lay-up and NSM bars.

Figure 10: Bridge X-495 [13] Figure 11: Bridge X-495 substructure [13]

Bridge P-962 Bridge P-962 is located on Hwy B and spans Dousinbury Creek in Dallas County, Missouri. This bridge was originally constructed in 1956 and consists of three simply supported spans all 42.5 feet long with a 23 foot wide deck. The 6 inch deck is supported by three tee beams spaced 9 feet on center [13]. Prior to strengthening the condition of the beams and piers were noted to be in good condition as shown in Figs. 12 and 13. P-962 was strengthened in flexure using NSM bars manual FRP lay-up and SRP. In order to place the SRP and FRP on bottom of the bents 20 ft3 (0.566 m3) of concrete needed to be removed. In addition, cleaning and substrate preparation was required for the SRP and FRP sheets.

Figure 12: Bridge P-962 [13]

Figure 13: Bridge P-962 substructure [13]

Bridge Y-298 Bridge Y-298 is located on Hwy U and spans Crews Branch Creek in Pulaski County Missouri. This bridge consists of two continuous spans each 15 ft. (4.57 m) long, 7 in. (178 mm) deep and 27 ft. (8.23 m) wide [13]. Prior to strengthening it was noted that the east span was in poor condition, especially close to the edge of the bridge due to poor drainage. Y-298 employed the use of two strengthening techniques for flexure. The first was FRP manual lay-up, which was difficult to install due to the poor condition of the concrete substrate. The second strengthening involved the use of MF-CFRP laminates.


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CONCLUSIONS This paper provides an overview of FRP bridge projects conducted within the State of Missouri, USA. The projects demonstrated various strengthening and new construction practices that have been successfully implemented. Many of these projects have included long-term monitoring to aid in the validation process of these new technologies. REFERENCES

1. Alkhrdaji, T. and A. Nanni, Design, Construction, and Field -Testing of an RC Box Culvert Bridge Reinforced with GFRP Bars, in Non-Metallic Reinforcement for Concrete Structures-FRPRCS-5. 2001: Cambridge, England, UK.

2. Watkins, S.E., et al., Instrumentation and Manufacture of a Smart Composite Bridge for Short-span Applications, in 8th Annual International Symposium on Smart Structures and Materials: Smart Systems for Bridges, Structures, and Highways, PROC. SPIE 4330. 2001: Newport Beach, CA, USA.

3. Stone, D.K., Investigation of FRP Materials for Bridge Construction, in Civil Engineering. 2002, University of Missouri-Rolla, Rolla, MO, USA. p. 213.

4. Galati, N., A. Prota, and R. Fico, Design Construction and Field Validation of the Southview Bridge in Rolla, Missouri, in International Bridge Conference. 2006.

5. Mayo, R., A. Nanni, and M. Barker. Strengthening of Bridge G270 with Externally-Bonded CFRP Reinforcement. in 4th International Symposium on FRP for Reinforcement of Concrete Structures (FRPRCS4). 1999. Baltimore, MD, USA.

6. Alkhrdaji, T., et al., Destructive and Non-Destructive Testing of Bridge J857, Phelps County, Missouri, in Research, Development and Technology, MoDOT, Editor. 2001, University of Missouri-Rolla, Rolla, MO, USA. p. 45.

7. Tumialan, J.G., P.-C. Huang, and A. Nanni, Strengthening of an Impacted PC Girder on Bridge A10062, in Research, Development and Technology, MoDOT, Editor. 2001, University of Missouri-Rolla, Rolla, MO, USA. p. 33.

8. Schiebel, S., R. Parretti, and A. Nanni, Repair and Strengthening of Impacted PC Girders on Bridge A4845 Jackson County, Missouri, in Research, Development and Technology, MoDOT, Editor. 2001, University of Missouri-Rolla, Rolla, MO, USA. p. 21.

9. Nanni, A., Strengthening of an Impact-Damaged PC Girder, in Concrete Repair Bulletin. 2004. p. 16-20.

10. Nanni, A., et al., Assessment and Rehabilitation of West 7th Street Bridge, City of Fulton, U.S. DOT, Editor. 2002. p. 39.

11. Schiebel, S., et al., Strengthening and Load Testing of Three Bridges in Boone County, Missouri. Practice Periodical on Structural Design and Construction, 2002(November): p. 156-163.

12. Casadei, P., N. Galati, and A. Nanni, Strengthening of Martin Springs Outer Road Bridge, Phelps County , in Research, Development and Technology, MoDOT, Editor. 2004, University of Missouri-Rolla, Rolla, MO, USA. p. 78.

13. Merkle, W.J., Load Distribution and Response of Bridges Retrofitted with Various FRP Systems, in Civil Engineering. 2004, University of Missouri-Rolla, Rolla, MO, USA. p. 180.

14. Rizzo, A., Application of Mechanically Fastened FRP (MF-FRP) Pre-cured Laminates in Off-system Bridges, in Engineering Mechanics. 2005, University of Missouri-Rolla, Rolla, MO, USA. p. 269.

15. Matta, F., et al., Pultruded FRP Reinforcement for Bridge Repair, in Composites Manufacturing. 2006. p. 18-24.

an overview of composites usage in bridge facilities...

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