Rehabilitation of Cracked Aluminum Connections with GFRP Composites for Fatigue Stresses

The original design of existing aluminum overhead sign structures (OSS) did not consider fatigue as a limit state. Cracks propagate in the welds of the connection between the main chord and branches of OSS due to fatigue stresses caused by wind-induced vibration, which occasionally lead to complete fracture of the welds. A rehabilitation method for cracked aluminum welded connections using glass fiber-reinforced Polymer (GFRP) composites is investigated for its effectiveness under fatigue stresses. The results of constant amplitude fatigue tests for three types of aluminum connections from actual OSS are presented: (1) connections with no known cracks; (2) cracked connections rehabilitated with GFRP composites; and (3) connections with 90% of the weld removed and subsequently repaired with GFRP composites. The fatigue limits of the three connection types are established for four stress ranges including the constant amplitude fatigue limit threshold. The rehabilitated connections from OSS exceeded the fatigue limit of the aluminum welded connections with no known cracks. The repaired connections with 90% of the weld removed satisfied the constant amplitude fatigue limit threshold. A cumulative damage index is established which leads to a fatigue reduction factor for the rehabilitation design of cracked aluminum connections using the GFRP composites.     

CFRP Composite Connector for Concrete Members

Steel plate connections are frequently used in tilt-up and precast concrete building construction to tie adjacent wall panels together for shear and overturning effects, and to provide continuous diaphragm chord connections for wind and seismic loading. These welded connectors perform poorly in regions of high seismicity and are vulnerable to corrosion. Until now, retrofit and repair strategies for in-plane shear transfer strengthening were limited to attaching steel sections across panel edges. In the present paper, an experimental program is described that utilizes carbon fiber reinforced plastic (CFRP) composites to develop a viable retrofit scheme for precast concrete shear walls and diaphragms. Nine full-scale precast wall panel assemblies with CFRP composite connectors have been tested. The results show that the CFRP composite connection is an effective solution for the seismic retrofit and repair of precast concrete wall assemblies and other precast concrete elements, such as horizontal diaphragms, that require in-plane shear transfer strengthening.     

Fabrication and Testing of Cuff Connections for GFRP Box Sections

A new type of connection between beams and columns has been designed and fabricated specifically for use with glass fiber reinforced plastic (GFRP) pultruded box members. The work is built on previous efforts in the area of GFRP connections, which demonstrated that innovative connections between box sections are superior to connections based on concepts from steel construction for connecting I-beams. The new connection element is designed as a monolithic connection for frame members and is fabricated using a vacuum assisted resin transfer molding process. Individual connection specimens have been fabricated and tested to verify their performance under cyclic static loads in a test frame designed to simulate conditions in a moment resisting frame. The connection configuration was found to fare better from the standpoint of both strength and stiffness in comparison with previous attempts at developing GFRP beam-to-column connections.     

Fatigue Behavior and Retrofit Investigation of Distortion-Induced Web Gap Cracking

This paper studies a Kansas Department of Transportation welded plate girder bridge that developed fatigue cracks at small web gaps close to the girder top flange. Repair had been previously performed by softening the connection plate end with a slot retrofit, but cracks were recently found to have reinitiated at some of the repaired details and are again propagating. A comprehensive finite-element method study was performed to investigate the cracking behavior observed in the bridge and to recommend appropriate measures for future bridge retrofit. The analytical results show that stresses developed at the top flange web gaps could exceed yielding under the loading of an HS15 fatigue truck. The current slot repair used in the bridge was found to have introduced higher magnitude fatigue stresses in the web gap. To achieve a permanent repair of the bridge, it is recommended that a welded connection plate to flange attachment be used during future bridge retrofit. The web gap details should be able to withstand unlimited number of load cycles once this additional repair is performed.     

End Connection Effects on Vortex Shedding Susceptibility of Welded Aluminum Truss Tubular Web Members

A series of experiments and analyses have been conducted to assess the vulnerability of hollow circular web members in welded aluminum sign truss structures to wind-induced resonant vibrations. Results from nondestructive field testing were used to develop and verify a reliable method for determining the fundamental natural frequency of vibration for various categories of truss web members (incorporating end connection fixity effects). These natural frequencies for different types, sizes, and lengths of web members were then related to their computed vortex-shedding frequencies, toward estimating the critical wind speeds for web member resonant vibration. Outcomes were correlated with wind-related fatigue damage observed in the field; simple design recommendations for preventing this sort of damage by limiting the maximum web member slenderness ratio have been developed.     

Static and Fatigue Behavior of Thick Pultruded GFRP Plates with Surface Damage

Glass fiber-reinforced polymer (GFRP) bridge decks suffering frequent cyclic loading of heavy wheels require relatively thick pultruded composites. To examine the behavior of 12 mm thick pultruded GFRP plates containing surface layers and to study the influence of surface damage, which may be present on such decks, static and fatigue tensile tests were carried out. Severe indentation yielded not only visible damage, but also an invisible damage in the unidirectional layer. Loss of cross section area due to both damages affected the static ultimate loads. Fatigue cracks were found around higher stress concentrations on the surface layer as early as approximately 10% of the total fatigue life. These initial cracks, however, barely affected the fatigue life because delamination of the surface layers prevented the cracks from propagating. The invisible shear crack due to indentation barely affected the fatigue life since earlier splitting between initially damaged and undamaged fibers mitigated the crack propagation.     

Full-Scale Fatigue Tests of Steel Orthotropic Decks for the Williamsburg Bridge

Final design of the replacement orthotropic deck panels for the rehabilitation of the Williamsburg Bridge in New York City was based on laboratory fatigue tests of a full-scale prototype and an as-built orthotropic deck panel carried out at Lehigh University in the latter 1990s. The tests focused on determining and comparing the fatigue resistance of two different welded rib-to-diaphragm connection details that were recommended in the 1994 AASHTO LRFD Bridge Design Specifications and an alternative proposed by Steinman. The test on the prototype panel demonstrated that the fatigue resistance of the alternative detail was superior and influenced additional design changes that were incorporated into the replacement panels installed on the southern inner and outer roadways. Subsequent tests on the as-built panel further confirmed that the fatigue resistance of the alternative detail was superior and demonstrated that the additional design changes were also beneficial. Static and dynamic tests revealed the complex behavior of the orthotropic deck panels and demonstrated the effectiveness of retrofit and repair options at cracked connections. An assessment of fatigue resistance based on fracture mechanics models provided theoretical correlation. This research has led to the revision of design specifications for steel orthotropic decks first provided in the 2000 Interim AASHTO LRFD Specifications.     

Seismic Retrofit of State Street Bridge on Interstate 80

The State Street Bridge, in Salt Lake City, was designed and built in 1965 according to the 1961 AASHO specifications; the design did not include earthquake-induced forces or displacements since only wind loads were considered. The bridge consists of four reinforced concrete (RC) bents supporting composite welded steel girders; the bents are supported on cast-in-place concrete piles and pile caps. A vulnerability analysis of the bridge was conducted that determined deficiencies in (1) confinement of column lap splice regions, (2) anchorage of longitudinal column bars in the bent cap, (3) confinement of column plastic hinge zones, and (4) shear capacity of columns and bent cap–column joints. Seismic retrofit designs using carbon-fiber-reinforced-polymer (CFRP) composites and steel jackets were performed and compared for three design spectra, including the 10% probability of exceedance in 250 years earthquake. The CFRP composite design was selected for implementation and application of the composite was carried out in the summer of 2000 and 2001, while the bridge was in service. The paper describes the CFRP composite design, which, in addition to column jackets, implemented an “ankle wrap” for improving joint shear strength and a “U-strap” for improving anchorage of column bars in the bent cap; other retrofit measures were implemented, such as bumper brackets and a deck slab retrofit. A capacity versus demand evaluation of the as-built and retrofitted bents is presented.     

Fatigue Strength of Repaired Prestressed Composite Beams

Composite steel-concrete bridges constitute a major portion of the national bridge inventory. Many of these structures are approaching or have passed their service lives and are in need of repair and rehabilitation. External prestressing by means of high-strength bars or cables attached to the steel beams has been used as an effective technique for upgrading the load carrying capacity of composite steel-concrete girders. While several researchers have investigated the static behavior of prestressed composite beams, few have reported on the fatigue strength of this structural system. The writers present the results of the experimental and analytical study of ten composite girders that were prestressed with seven-wire strands and then fatigue tested to failure. Three methods of extending the fatigue life of cracks were then explored: (1) drilling a hole at the crack tip and installing a high-strength bolt; (2) splicing the web at the cracked section; and (3) increasing the prestressing force of the tendon. The efficacy of the three methods is compared.     

Static and Fatigue Testing of Hybrid Fiber-Reinforced Polymer-Concrete Bridge Superstructure

This paper presents the experimental results from static and fatigue testing on a scale model of a hybrid fiber-reinforced polymer (FRP)–concrete bridge superstructure. The hybrid superstructure was designed as a simply-supported single span bridge with a span of 18.3 m. Three trapezoidal glass fiber-reinforced polymer (GFRP) box sections are bonded together to make up a one-lane superstructure, and a layer of concrete is placed in the compression side of those sections. This new design was proposed in order to reduce the initial costs and to increase the stiffness of GFRP composite structures. Static test results showed that the bridge model meets the stiffness requirement and has significant reserve strength. The bridge model was also subjected to two million load cycles to investigate its fatigue characteristics. The fatigue testing revealed that the structural system exhibits insignificant stiffness degradation.     

Strengthening of Reinforced Concrete Bridge Decks Using Carbon Fiber-Reinforced Polymer Composite Materials

This paper presents the results of an investigation of the monotonic and fatigue behavior of one-way and two-way reinforced concrete slabs strengthened with carbon fiber-reinforced polymer (CFRP) materials. The five one-way slab specimens were removed from a decommissioned bridge in South Carolina. Three of the slabs were retrofitted with CFRP strips bonded to their soffits and the other two served as unretrofit, control specimens. Of the five one-way slab specimens, one unretrofit and two retrofit slabs were tested monotonically until failure. The remaining two specimens, one unretrofit and one retrofit, were tested under cyclic (fatigue) loading until failure. In addition, six half-scale, two-way slab specimens were constructed to represent a full-scale prototype of a highway bridge deck designed using the empirical requirements of the AASHTO LRFD Bridge Design Manual. Of the six square slabs, two were unretrofitted and served as the control specimens, two were retrofitted using CFRP strips bonded to their soffits making a grid pattern, and two were retrofitted with a preformed CFRP grid material bonded to their soffit. Three slabs, one unretrofit, one CFRP strip, and one CFRP grid retrofitted, were tested monotonically until failure and the remaining three slabs were tested under cyclic (fatigue) loading until failure.     

Repair of Slab–Column Connections Using Epoxy and Carbon Fiber Reinforced Polymer

Repair, strengthening, and retrofit of reinforced and prestressed concrete members have become increasingly important issues as the World’s infrastructure deteriorates with time. Buildings and bridges are often in need of repair or strengthening to accommodate larger live loads as traffic and building occupancies change. In addition, inadequate design and detailing for seismic and other severe natural events has resulted in considerable structural damage and loss of life, particularly in reinforced concrete buildings. Numerous buildings and bridges suffer damage during such events and need to be repaired. The use of carbon fiber reinforced polymer (CFRP) composite fabric bonded to the surface of concrete members is comparatively simple, quick and virtually unnoticeable after installation. The use of composites has become routine for increasing both the flexural and shear capacities of reinforced and prestressed concrete beams. Earthquake retrofit of bridge and building structures has relied increasingly on composite wrapping of columns, beams and joints to provide confinement and increase ductility. This paper presents the results of cyclic testing of three large-scale reinforced concrete slab–column connections. Each of the specimens was a half-scale model of an interior slab–column connection common to flat-slab buildings. The specimens were reinforced according to ACI-318 code requirements and included slab shear reinforcement. While supporting a slab gravity load equivalent to dead load plus 30% of the live load, the specimens were subjected to an increasing cyclic lateral loading protocol up to 5% lateral drift. The specimens were subjected to the same loading protocol after they were repaired with epoxy crack sealers and CFRP sheet on the surfaces of the slab. Repair with epoxy and CFRP on the top surface of the slab was able to restore both initial stiffness and ultimate strength of the original specimen.     

Full-Scale Testing and Analysis for Blast-Resistant Design

A full-scale blast test was conducted on a structure representing a mailroom, constructed with unreinforced masonry walls. The four walls were retrofitted with different quantities of glass fiber-reinforced polymers (GFRP) on the outside face to increase their resistance to the blast load. In addition, shotcrete was added to the inside face of the two long walls. The objective of this test was to validate a method of analysis that can be used to design effective retrofit techniques to contain blast loads. A blast load was produced by the detonation of a 0.91?kg (2?lb) equivalent TNT charge placed near the center of the room. Instrumentation on individual walls monitored the blast pressure and the consequent displacement and velocity of the walls. Although the walls sustained extensive internal damage and plastic deformation, the retrofit was able to withstand the blast load. It was observed through the postmortem analysis of the test that the stiffness of the walls is completely lost at an early stage and only membrane action of the GFRP provides structural resistance.     

Effects of Variation of Axial Load and Bidirectional Loading on Seismic Performance of GFRP Retrofitted Reinforced Concrete Exterior Beam-Column Joints

Most of the experimental studies available in literature on the seismic assessment and retrofit of existing, poorly detailed, reinforced concrete (RC) beam-column joints, typical of pre-1970s construction practice, have concentrated on the two-dimensional (2D) response, using unidirectional cyclic loading testing protocol and constant axial load. Even more limited information is available on the performance of exterior (corner) three-dimensional (3D) RC beam-column joints with substandard detailing subjected to bidirectional loading regime. In this study, the results of a comprehensive experimental program is presented, aiming to show the effects of varying axial and bidirectional loading on the seismic performance of deficient exterior RC beam-column joints before and after retrofit. Ten exterior beam-column joint subassemblies are tested, including four as-built specimens and six retrofitted specimens using externally bonded glass fiber-reinforced polymer (GFRP) sheets. Test results are herein presented and conclusions are drawn on the basis of the observed global and local performance. The significance of the triaxial interaction of varying axial and bidirectional loading effects on the response of retrofitted corner joints is confirmed by the experimental findings. The proposed retrofit solution was shown to be capable of re-establishing an appropriate hierarchy of strength within the subassembly, protecting the panel zone region from shear failure while promoting the formation of a plastic hinge in the beam.     

Case Study: Seismic Retrofitting of a Medieval Bell Tower with FRP

Seismic retrofitting of monument structures requires compliance with restrictive constraints related to the preservation of original artistic and structural features. Any conceived intervention must achieve structural performance yet still respect the appearance and structural mechanism of the original and be as minimally invasive as possible. Therefore, traditional retrofit strategies may not be suitable for such purposes, and structural engineers need to develop specific techniques. Innovative materials (e.g., composites) may be helpful, as demonstrated by the case study presented in this paper. Fiber-reinforced plastics (FRPs) were used for the design, analysis, and installation of the retrofit for the medieval bell tower in Serra San Quirico (Ancona, Italy). A FRP tie system is applied to the inner walls and anchored at the base by a reinforced concrete slab, independent of the tower’s foundation. The intervention enhances the seismic capacity of the structure and is fully provisional as it may be removed by heating the FRP with a hot air jet. The design process consisted of preliminary finite-element simulation and on-site structural assessment. Effectiveness is evaluated by a comparison of nonlinear static analyses (pushover) of the retrofitted and original structures. Finally, seismic risk reduction is computed by considering probabilistic seismic hazard at the site. Installation issues and the current appearance of the structure are also discussed.     

采用爆炸-轧制法制备钛/铝复合板

主要对制备1．5mm钛／铝复合薄板的爆炸一轧制工艺进行了实验研究。通过实验，确定了TA1和2A12这两种合金的爆炸焊接工艺参数。为了解决单张复合板在轧制过程中缠绕轧辊的问题，提出了两张爆炸焊接钛／铝复合板的对称轧制工艺，并且得到了成功的应用。对于轧制过程中复合板钛层表面出现的间歇性开裂现象，也进行了详细的分析。两种基体金属流动变形的不同步性以及铝对钛产生的不均匀牵引变形力是导致复合板钛层表面开裂的主要原因。     

Performance-Based Seismic Retrofit Strategy for Existing Reinforced Concrete Frame Systems Using Fiber-Reinforced Polymer Composites

The feasibility and efficiency of a seismic retrofit intervention using externally bonded fiber-reinforced polymer composites on existing reinforced concrete frame systems, designed prior to the introduction of modern standard seismic design code provisions in the mid-1970s, are herein presented, based on analytical and experimental investigations on beam-column joint subassemblies and frame systems. A multilevel retrofit strategy, following hierarchy of strength considerations, is adopted to achieve the desired performance. The expected sequence of events is visualized through capacity-demand curves within M-N performance domains. An analytical procedure able to predict the enhanced nonlinear behavior of the panel zone region, due to the application of CFRP laminates, in terms of shear strength (principal stresses) versus shear deformation, has been developed and is herein proposed as a fundamental step for the definition of a proper retrofit solution. The experimental results from quasi-static tests on beam-column subassemblies, either interior and exterior, and on three-storey three-bay frame systems in their as-built and CFRP retrofitted configurations, provided very satisfactory confirmation of the viability and reliability of the adopted retrofit solution as well as of the proposed analytical procedure to predict the actual sequence of events.     

Potential Retrofit Methods for Concrete Channel Beam Bridges Using Glass Fiber Reinforced Polymer

The structural response of deteriorated channel beam bridge girders and channel beam bridge decks with and without glass fiber reinforced polymer (GFRP) retrofit is found from design calculations, experimental load testing, and finite element analysis. Two different types of GFRP retrofit materials are investigated including a traditional fabric wrap and a new spray material. The effects of GFRP retrofit on channel beam bridge girder and channel beam bridge structural parameters are summarized and the accuracy of design calculation methods for quantifying structural response of channel beam bridge girders retrofit with GFRP is determined.