Enhancement of Welded Steel Bridge Girders Susceptible to Distortion-Induced Fatigue

The goal of this study was to develop and evaluate the performance of retrofit techniques for existing steel bridges that have already sustained damage due to distortion-induced fatigue, or are anticipated to experience distortion-induced fatigue cracking within their design life. A second goal was to evaluate the use of new technologies and materials for repairing distortion-induced fatigue damage in steel bridges. While a number of retrofit techniques exist for repairing distortion-induced fatigue cracking, many of them require partial or full bridge closure to perform the repair. The retrofits developed under this project are intended to be able to be installed with minimal disturbance to traffic. Four primary subject matters are reported on within this document: (1) the development of the “angles-with-plate” distortion-induced fatigue repair; (2) development of fiber reinforced polymer (FRP) repairs for distortion-induced fatigue and in-plane fatigue; (3) development of Piezoelectric Induced Compressive Kinetics (PICK) technology for treatment of crack-arrest holes; and (4) a series of analytical investigations aimed at better understanding distortion-induced fatigue susceptibility of skewed bridge systems.

[1]  Scott A. Civjan,et al.  APPLICATION OF FIBER REINFORCED POLYMER OVERLAYS TO EXTEND STEEL FATIGUE LIFE , 2003 .

[2]  Ron Barrett,et al.  Fatigue Enhancement of Welded Coverplates Using Carbon-Fiber Composites , 2008 .

[3]  J. M. Stallings,et al.  Laboratory Tests of Bolted Diaphragm-Girder Connections , 1998 .

[4]  Arturo E Schultz,et al.  Analysis of Girder Differential Deflection and Web Gap Stress for Rapid Assessment of Distortional Fatigue in Multi-Girder Steel Bridges , 2005 .

[5]  O. Büyüköztürk,et al.  Progress on understanding debonding problems in reinforced concrete and steel members strengthened using FRP composites , 2004 .

[6]  John W. Fisher,et al.  FATIGUE CRACKING IN WELDED STEEL BRIDGES , 1990 .

[7]  R. Hermann,et al.  Effect of expansion technique and plate thickness on near-hole residual stresses and fatigue life of cold expanded holes , 1999 .

[8]  A. J. Mcevily,et al.  Analysis of the effect of cold-working of rivet holes on the fatigue life of an aluminum alloy , 2007 .

[9]  P. Colombi,et al.  Crack growth induced delamination on steel members reinforced by prestressed composite patch , 2003 .

[10]  John W. Fisher,et al.  Identifying Effective and Ineffective Retrofits for Distortion Fatigue Cracking in Steel Bridges Using Field Instrumentation , 2006 .

[11]  Katsuyoshi Nozaka,et al.  Design of a Test Specimen to Assess the Effective Bond Length of Carbon Fiber-Reinforced Polymer Strips Bonded to Fatigued Steel Bridge Girders , 2005 .

[12]  Kevin T. Canning.  Bridge Design Manual , 2005 .

[13]  P. Mallick.  Fiber-reinforced composites : materials, manufacturing, and design , 1989 .

[14]  Temple Richardson.  Analytical Investigation of Repair Methods for Fatigue Cracks in Steel Bridges , 2012 .

[15]  Q. Y. Wang,et al.  Fatigue crack growth behavior of bonded composite repairs , 2002, International Conference on Experimental Mechanics.

[16]  Wei Jiang,et al.  Experimental study on repair of fatigue cracks at welded web gusset joint using CFRP strips , 2009 .

[17]  Brad Petri.  Finite element analysis of steel welded coverplate including composite doublers , 2008 .

[18]  Alain Nussbaumer,et al.  Analysis of cracked steel members reinforced by pre-stress composite patch , 2003 .

[19]  G Marquis,et al.  FATIGUE TESTING AND ANALYSIS USING THE HOT SPOT METHOD , 1995 .

[20]  Caroline Bennett,et al.  Use of CFRP Overlays to Strengthen Welded Connections under Fatigue Loading , 2012 .

[21]  Modeling and validation of composite patch repair to cracked thick and thin metallic panels , 2009 .

[22]  S. Mall,et al.  Characterization of disbond effects on fatigue crack growth behavior in aluminum plate with bonded composite patch , 1997 .

[23]  Cgc Poussard,et al.  Analytical and finite element predictions of residual stresses in cold worked fastener holes , 1995 .

[24]  J. Przywara.  Applications of the Extended Finite Element Method (XFEM) for the Analysis of Distortion-Induced Fatigue Cracking in Highway Bridge Girders , 2013 .

[25]  Carlo Poggi,et al.  Fatigue performance of tensile steel members strengthened with CFRP plates , 2009 .

[26]  John W. Fisher,et al.  FATIGUE STRENGTH ENHANCEMENT BY MEANS OF WELD DESIGN CHANGE AND THE APPLICATION OF ULTRASONIC IMPACT TREATMENT , 2001 .

[27]  D. Griffin,et al.  Finite-Element Analysis , 1975 .

[28]  Agostino Lanciotti,et al.  The effect of interference fit fasteners on the fatigue life of central hole specimens , 2005 .

[29]  J. Fisher,et al.  FATIGUE AND FRACTURE IN STEEL BRIDGES , 1984 .

[30]  Karl H. Frank,et al.  Evaluation of Influence of Hole Making Upon the Performance of Structural Steel Plates and Connections , 2007 .

[31]  Shankar Mall,et al.  Investigation into cracked aluminum plate repaired with bonded composite patch , 2007 .

[32]  Robert Edward Kenneth. Fraser.  Behaviour of distortion-induced fatigue cracks in bridge girders , 2000 .

[33]  David J. Goodman,et al.  Personal Communications , 1994, Mobile Communications.

[34]  Y. Edward Zhou,et al.  Investigation of Large Web Fractures of Welded Steel Plate Girder Bridge , 2010 .

[35]  Katsuyoshi Nozaka,et al.  Effective bond length of carbon-fiber-reinforced polymer strips bonded to fatigued steel bridge I-girders , 2005 .

[36]  Željko Domazet,et al.  Comparison of fatigue crack retardation methods , 1996 .

[37]  Donald W. White,et al.  Recommended Procedures for Simplified Inelastic Design of Steel I-Girder Bridges , 2004 .

[38]  Caroline Bennett,et al.  Parametric Analysis of Cross-Frame Layout on Distortion-Induced Fatigue in Skewed Steel Bridges , 2013 .

[39]  Caroline Bennett,et al.  Distortion-Induced Fatigue in Steel Bridges: Causes, Parameters, and Fixes , 2010 .

[40]  John W. Fisher,et al.  FATIGUE BEHAVIOR OF VARIABLE LOADED BRIDGE DETAILS NEAR THE FATIGUE LIMIT , 1987 .

[41]  Efim Statnikov,et al.  PHYSICS AND MECHANISM OF ULTRASONIC IMPACT TREATMENT , 2004 .

[42]  M. González.  7. Results and Discussion , 2001 .

[43]  John W. Fisher,et al.  DISTORTION-INDUCED FATIGUE CRACKING IN STEEL BRIDGES , 1990 .

[44]  M-H Kim,et al.  Testing and analysis of fatigue behaviour in edge details: A comparative study using hot spot and structural stresses , 2008 .

[45]  I. M. May,et al.  Modelling composite repairs to cracked metal structures , 2009 .

[46]  Shankar Mall,et al.  INVESTIGATION OF A CRACKED THICK ALUMINUM PANEL REPAIRED WITH A BONDED COMPOSITE PATCH , 1999 .

[47]  Robert J. Dexter,et al.  Manual for Repair and Retrofit of Fatigue Cracks in Steel Bridges , 2013 .

[48]  P.M.S.T. de Castro,et al.  Numerical simulation of cold working of rivet holes , 2005 .

[49]  Stanley T. Rolfe,et al.  Fracture and Fatigue Control in Structures: Applications of Fracture Mechanics , 1976 .

[50]  Caroline Bennett,et al.  Development of a Technique to Improve Fatigue Lives of Crack-Stop Holes in Steel Bridges , 2010 .

[51]  Joseph W. Tedesco,et al.  Finite element method analysis of bridge girder-diaphragm interaction , 1995 .

[52]  S. Mall,et al.  Fatigue crack growth analysis of stiffened cracked panel repaired with bonded composite patch , 2006 .

[53]  F. Alemdar.  USE OF COMPOSITE MATERIALS TO REPAIR STEEL STRUCTURES VULNERABLE TO FATIGUE DAMAGE , 2010 .

[54]  Todd A. Helwig,et al.  Stability bracing requirements for steel bridge girders with skewed supports , 2008 .

[55]  Mark D. Bowman,et al.  Fatigue Behavior of Welded Diaphragm-to-Beam Connections , 2001 .

[56]  Terry J Wipf,et al.  RETROFIT SOLUTION FOR OUT-OF-PLANE DISTORTION OF X-TYPE DIAPHRAGM BRIDGES , 1998 .

[57]  Amr Daniel Nagati.  REPAIR OF STEEL BRIDGE GIRDERS DAMAGED BY DISTORTION-INDUCED FATIGUE , 2012 .

[58]  Shankar Mall,et al.  Modeling of a cracked metallic structure with bonded composite patch using the three layer technique , 1996 .

[59]  Ronald M. Barrett-Gonzalez,et al.  Improved Method for Bonding CFRP Overlays to Steel for Fatigue Repair , 2011 .

[60]  Dennis R. Mertz,et al.  NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM 227 REPORT FATIGUE BEHAVIOR OF FULL-SCALE WELDED BRIDGE ATTACHMENTS , 2015 .

[61]  Karl H. Frank,et al.  Improved Cross-Frame Connection Details for Steel Bridges with Skewed Supports , 2010 .

[63]  Dl Ball,et al.  Experimental investigation on the effects of cold expansion of fastener holes , 1998 .

[64]  Pedro Albrecht,et al.  Fatigue-Proofing Cover Plates , 2007 .

[65]  Peter B. Keating.  FOCUSING ON FATIGUE , 1994 .

[66]  R. Al-Mahaidi,et al.  Prediction of fatigue life for CFRP-strengthened steel plates , 2009 .

[67]  Yuan Zhao,et al.  Fatigue Behavior and Retrofit Investigation of Distortion-Induced Web Gap Cracking , 2007 .

[68]  Gary Gene Simmons,et al.  Fatigue Enhancement of Undersized, Drilled Crack-Arrest Holes , 2013 .

[69]  W. N. Sharpe,et al.  Measurement of the Elastic-Plastic Boundary Around Coldworked Fastener Holes , 1978 .

[70]  S. J. Maddox.  Hot-Spot Stress Design Curves For Fatigue Assessment of Welded Structures , 2002 .

[71]  Howard E. Boyer,et al.  Atlas of stress-strain curves , 1987 .

[72]  D. Rooke,et al.  the compounding method applied to cracks in stiffened sheets , 1976 .

[73]  Arturo E. Schultz,et al.  Measurement and analysis of distortion-induced fatigue in multigirder steel bridges , 2003 .

[74]  Gérard Mesmacque,et al.  Fatigue life estimation after crack repair in 6005 A-T6 aluminium alloy using the cold expansion hole technique , 2000 .

[75]  Jm Barsom,et al.  Effect of Stress Concentration on Fatigue-Crack Initiation in HY-130 Steel , 1974 .

[76]  John W. Fisher,et al.  Evaluation of fatigue cracking at cross diaphragms of a multigirder steel bridge , 1988 .

[77]  Benjamin Nicolaas Kaan.  Fatigue enhancement of Category E' details in steel bridge girders using CFRP materials , 2008 .

[78]  J. M. Stallings,et al.  REMOVAL OF DIAPHRAGMS FROM THREE-SPAN STEEL GIRDER BRIDGE , 1999 .

[79]  Chow-Shing Shin,et al.  Fatigue damage repair: a comparison of some possible methods , 1996 .

[80]  Ma Landy,et al.  Enhanced Stop-Drill Repair Procedure for Cracked Structures , 1986 .

[81]  Heidi L. Hassel.  An Analytical Evaluation of Distortion-Induced Fatigue in Steel Bridges , 2011 .

[82]  F. Hauser,et al.  Deformation and Fracture Mechanics of Engineering Materials , 1976 .

[83]  Karen Willcox,et al.  Kinetics and kinematics for translational motions in microgravity during parabolic flight. , 2009, Aviation, space, and environmental medicine.

[84]  Yuan Zhao,et al.  Finite-Element Analysis of Steel Bridge Distortion-Induced Fatigue , 2003 .

[85]  Regan Elisabeth Gangel.  Use of CFRP Overlays to Repair Fatigue Damage in Steel Bridge Girders and Components , 2012 .

[86]  Caroline Bennett,et al.  Fatigue Enhancement of Welded Details in Steel Bridges Using CFRP Overlay Elements , 2012 .

[87]  Cgc Poussard,et al.  Effect of residual stress around cold worked holes on fracture under superimposed mechanical load , 1999 .

[88]  Brian Vilhauer.  Fatigue behavior of welded connections enhanced with UIT and bolting , 2007 .

[89]  Arturo E. Schultz,et al.  Girder Differential Deflection and Distortion-Induced Fatigue in Skewed Steel Bridges , 2006 .

[90]  Jung-Ju Lee,et al.  Successive 3D FE analysis technique for characterization of fatigue crack growth behavior in composite-repaired aluminum plate , 2004 .

[91]  P. Colombi,et al.  Repair of riveted bridge members damaged by fatigue using CFRP materials , 2000 .

[92]  Yuan Zhao,et al.  Finite Element Study of Distortion-Induced Fatigue in Welded Steel Bridges , 2003 .

[93]  Mw Ozelton,et al.  Fatigue Life Improvement by Cold Working Fastener Holes in 7050 Aluminum , 1986 .

[94]  Caroline Bennett,et al.  Effects of Cross-Frame Placement and Skew on Distortion-Induced Fatigue in Steel Bridges , 2010 .

[95]  S. Mall,et al.  Modeling of cracked thick metallic structure with bonded composite patch repair using three-layer technique , 1999 .

[96]  A. Leon,et al.  Benefits of split mandrel coldworking , 1998 .

[97]  Harold S. Reemsnyder.  Fatigue Life Extension of Riveted Connections , 1975 .

[98]  D. L. Ball,et al.  ELASTIC‐PLASTIC STRESS ANALYSIS OF COLD EXPANDED FASTENER HOLES , 1995 .

[99]  William Wright.  POST-WELD TREATMENT OF A WELDED BRIDGE GIRDER BY ULTRASONIC IMPACT TREATMENT , 1996 .

[100]  Hamid Saadatmanesh,et al.  Fatigue Strength of Steel Girders Strengthened with Carbon Fiber Reinforced Polymer Patch , 2003 .

[101]  Riadh Al-Mahaidi,et al.  Experimental study of fatigue crack growth behaviour in adhesively reinforced steel structures , 2009 .

[102]  T. Bui-Quoc,et al.  3-d Axisymmetric Numerical Analysis And Experimental Study Of The Fastener Hole Coldworking Process , 1970 .

[103]  Adolfo B. Matamoros,et al.  Design, modeling, and testing of a piezoelectric impact compressive kinetic (PICK) tool for crack-stop hole treatment , 2013, Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring.

[104]  John W. Fisher,et al.  Distortion-induced fatigue cracking of bridge details with web gaps , 1989 .

[105]  Ying Zhang,et al.  Analysis of the Residual Stress around a Cold‐expanded Fastener Hole in a Finite Plate , 2005 .

[106]  李幼升,et al.  Ph , 1989 .

[107]  Alain Nussbaumer,et al.  Crack repair and fatigue life extension of riveted bridge members using composite materials , 2000 .

[108]  Joshua Sakumura Crain,et al.  Fatigue Enhancement of Undersized, Drilled Crack-Stop Holes , 2010 .

[109]  Turaga V.R.S. Umamaheswar,et al.  Modelling of a patch repair to a thin cracked sheet , 1999 .

[110]  Wendel Michael Sebastian,et al.  Interface Failure Mechanics of Elastically "Advanced Composite… Reinforced Steel Members , 2007 .