ce 120 – introduction to civil engineering wednesday ...rsouley/ce 120/9/harik... · king cobra...

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


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


Carbon

Glass

Aramid

Boron

Nylon

Polyester

Polyethylene



• calcium carbonate• clay• talc• aluminum trihydrate• silica• micro spheres• mica


Function of Fillers• Improves mechanical

properties• Improves surface finish• Improves processibility• Lowers total part cost• Improves dimensional

stability• Reduces shrinkage


• catalysts & promoters

• inhibitors• release agent• pigments• uv absorber• fire retardant


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



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


Aluminum Deck Placement


Bridge Ready for TrafficAfter 2 Hours

Deck Connection to Steel Girders


Asphalt Topping

KY 270 BridgeWebster County, KY

July 30, 2009

KY 270 BridgeWebster County, KY


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


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


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


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

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60

80

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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

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90

100

0 2000 4000 6000 8000 10000

Elapsed time (Hr)

Tem

pera

ture

(o F)

0

10

20

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0 500 1000 1500 2000

Elapsed time (Hr)

Tem

pera

ture

(o F)

-10

-8

-6

-4

-2

0

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6

8

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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



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


(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


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


(without epoxy)(without epoxy)

CRP 195 Strength = 195,700 lbs/ft

Type 1 Truck W = 40,000 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

ce 120 – introduction to civil engineering wednesday ...rsouley/ce 120/9/harik... · king cobra...

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