Assessment of Bridge Remaining Fatigue Life through Field Strain Measurement

With the aging of existing steel bridges and the accumulated stress cycles under traffic loads, assessment of remaining fatigue life for continuing service has become more important than ever, especially for decisions on structure replacement, deck replacement, or other major retrofits. Experience from engineering practice indicates that fatigue analysis based on specification loads and distribution factors usually underestimates the remaining fatigue life of existing bridges by overestimating the live load stress ranges. Fatigue evaluation based on field-measured stress range histograms under actual traffic load proves to be a more accurate and efficient method for existing bridges. This paper describes the application of such a method in assessing the remaining fatigue life of bridge structures. Current AASHTO specifications for fatigue evaluation of existing bridges are reviewed and compared. Case studies of three major highway bridges are discussed. Finally, a procedure is proposed for evaluating fatigue life of existing bridges through field strain measurement.     

Extending the Fatigue Life of Riveted Coped Stringer Connections

Fatigue cracking occurs at the copes of stringer–floorbeam connections of older, riveted steel bridges. Some cracks are quite long and raise serious questions regarding the remaining fatigue life of the subject bridges. Damage limitation methods (DLMs) have been used to increase the fatigue life of these stringers, but the effectiveness of the DLMs for these riveted connections had never been evaluated by tests. Therefore, tests were conducted to evaluate the fatigue life of coped, riveted stringer–floorbeam connections, and the effectiveness of DLMs. Fatigue cracks in the coped stringer–floorbeam connection were initially developed to establish crack initiation requirements and the rate and extent of crack growth. Once a significant crack was noted, one of several DLMs was applied, and the specimens were retested to determine the effectiveness of the DLM in controlling cracking. These DLMs included the drilled hole, the inserted bolt and the removed rivet methods. The relative effectiveness of the methods is described, and a design procedure is proposed for improving their performance.     

Finite-Element Analysis of Steel Bridge Distortion-Induced Fatigue

Welded plate girder bridges built before the mid-1980s are often susceptible to fatigue cracking driven by out-of-plane distortion. However, methods for prediction of secondary stresses are not specifically addressed by bridge design specifications. This paper presents a finite-element study of a two-girder bridge that developed web gap cracks at floortruss-girder connections. The modeling procedures performed in this research provide useful strategies that can be applied to determine the magnitude of distortion-induced stresses, to describe the behavior of crack development, and to assess the effectiveness of repair alternatives. The results indicate severe stress concentration at the crack initiation sites. The current repair method used at the positive moment region connections is found acceptable, but that used at the negative moment region connections is not satisfactory, and additional floortruss member removal is required. Stress ranges can be lowered below half of the constant amplitude fatigue threshold, and fatigue cracking is not expected to recur if the proposed retrofit approach is carried out.     

Truck Models for Improved Fatigue Life Predictions of Steel Bridges

A new fatigue load model has been developed based on weigh-in-motion (WIM) data collected from three different sites in Indiana. The recorded truck traffic was simulated over analytical bridge models to investigate moment range responses of bridge structures under truck traffic loadings. The bridge models included simple and two?equally continuous spans. Based on Miner’s hypothesis, fatigue damage accumulations were computed for details at various locations on the bridge models and compared with the damage predicted for the 240-kN (54-kip) American Association of State Highway and Transportation Officials (AASHTO) fatigue truck, a modified AASHTO fatigue truck with an equivalent effective gross weight, and other fatigue truck models. The results indicate that fatigue damage can be notably overestimated in short-span girders. Accordingly, two new fatigue trucks are developed in the present study. A new three-axle fatigue truck can be used to represent truck traffic on typical highways, while a four-axle fatigue truck can better represent truck traffic on heavy duty highways with a significant percentage of the fatigue damage dominated by eight- to 11-axle trucks.     

Determining Appropriate Fatigue Inspection Intervals for Steel Bridge Members

As part of the National Bridge Inspection Standards, owners of public bridge structures are required to perform a Fracture Critical Inspection on steel superstructures that contain primary structural elements having no load path redundancy, e.g., two girder systems. Such inspections are looking to identify damage or deterioration such as corrosion and fatigue cracking that may lead to failure of the critical member. The Oregon Department of Transportation is responsible for the inspection of 196 fracture critical structures that are subjected to widely varying service and environmental conditions. These conditions range from coastal bridges in a fairly corrosive environment with moderate traffic volumes, to large and complex structures in urban areas that experience large volumes of traffic, to very benign conditions in the sparsely populated eastern regions with very low traffic volumes. In response to these widely varying service conditions, Oregon has developed a method to better categorize steel superstructures for fatigue inspection priority and frequency. This method is not only proving to save unnecessary inspection costs but increasing the inspection quality by concentrating resources where they are most needed. This paper presents a simple and practical method of evaluating fatigue inspection periods.     

Fatigue and Fracture of Steel Girders

This paper presents an overview of materials selection, design, and detailing of steel girders for fatigue and fracture limit states. The historical context of the fracture control plan for bridges is presented. A discussion of fracture toughness of structural steel and weld metal is presented along with typical Charpy and fracture-toughness test data, including the new high-performance steel A709 HPS 485W. Fatigue of cover plate details and distortion-induced cracking are discussed. Methods of dealing with variable-amplitude loading are then compared to test data.     

Fatigue Behavior of Composite-Reinforced Glulam Bridge Girders

While composite-reinforced glulam beams have been used in several bridge demonstration projects, knowledge of their fatigue behavior is quite limited. In this study, the response of full- and partial-length fiberglass composite-reinforced glulam beams under fatigue cycling followed by quasi-static bending to failure is examined. To mimic anticipated in-service conditions, a hygrothermal cycling regime was developed that replicates the effective stress history of a 50-year service life with a 55-day period in a moisture-controlled kiln. In addition, some of the beams had initial delaminations introduced between the reinforcing and the wood similar to those observed in field investigations of reinforced glulam bridge girders. For the partial-length reinforced beams, reinforcing with both confined and unconfined ends was considered. The results of the postfatigue tests to failure were compared with the expected strength. In addition, the stiffness of the beams was monitored during the fatigue cycling. It was found that, with the exception of the unconfined, partial-length reinforced beams, all specimens had a residual strength that compared favorably with the expected strength. Further, neither the preconditioning nor the fatigue cycling had an appreciable impact on the stiffness of the reinforced beams. The unconfined, partial-length reinforced beams did not perform well under fatigue loading and do not seem to be a viable alternative for use as reinforced glulam bridge girders.     

Measurement and Analysis of Distortion-Induced Fatigue in Multigirder Steel Bridges

Fatigue damage to multigirder steel bridges on skew can result from distortion caused by differential deflection of adjacent girders that impose out-of-plane bending of girder web gaps. Existing design procedures give recommendations to mitigate the effects of distortional fatigue but do not directly address secondary, out-of-plane deformations, nor do they provide guidance in determining the magnitude of out-of-plane stresses in girder webs. An experimental study was conducted to (1) implement a field monitoring program for a typical multigirder steel bridge on skew supports; (2) assess the frequency and magnitude of distortional fatigue stresses at web-stiffener connections; and (3) evaluate the impact of these stresses on fatigue life. Measurements from twelve strain gauges were continuously monitored and recorded for a period exceeding three months on Minnesota Department of Transportation Bridge #27734. Web-gap stresses in negative-moment regions were found to be much larger than flange stresses. The results of a detailed finite-element study indicate that actual strains at the web gaps may be much larger than the values measured at the strain gauge locations. This study also revealed the mechanism of web-gap distortion, suggesting an approximate method for predicting web-gap stress based on known girder differential deflection.     

Development and Implementation of a Continuous Strain Monitoring System on a Multi-Girder Composite Steel Bridge

This paper describes the implementation and evaluation of a long-term strain monitoring system on a three-span, multisteel girder composite bridge located on the interstate system. The bridge is part of a network of bridges that are currently being monitored in Connecticut. The three steel girders are simply supported, whereas the concrete slab is continuous over the interior supports. The bridge has been analyzed using the standard AASHTO Specifications and the analytical predictions have been compared with the field monitoring results. The study has included determination of the location of the neutral axes and the evaluation of the load distributions to the different girders when large trucks cross the bridge. A finite-element analysis of the bridge has been carried out to further study the distribution of live load stresses in the steel girders and to study how continuity of the slabs at the interior joints would influence the overall behavior. The results of the continuous data collection are being used to evaluate the influence of truck traffic on the bridge and to establish a baseline for long-term monitoring.     

Fatigue Damage of Steel Bridges Due to Dynamic Vehicle Loads

This paper focuses on the fatigue damage caused in steel bridge girders by the dynamic tire forces that occur during the crossing of heavy transport vehicles. This work quantifies the difference in fatigue life of a short-span and a medium-span bridge due to successive passages of either a steel-sprung or an air-sprung vehicle. The bridges are modeled as beams to obtain their modal properties, and air-sprung and nonlinear steel-sprung vehicle models are used. Bridge responses are predicted using a convolution method by combining bridge modal properties with vehicle wheel forces. A linear elastic fracture mechanics model is employed to predict crack growth. For the short-span bridge, the steel-sprung vehicle caused fatigue failure up to 6.5 times faster than the air-sprung vehicle. For the medium-span bridge, the steel-sprung vehicle caused fatigue failure up to 277 times faster than the air-sprung vehicle.     

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.     

Probabilistic Fatigue Evaluation of Riveted Railway Bridges

A probabilistic fatigue assessment methodology for riveted railway bridges is presented. The methodology is applied to a typical, short-span, riveted U.K. railway bridge under historical and present day train loading. On the loading side, the problem is randomized through dynamic amplification and traffic volume; on the resistance side, the S-N curves and the cumulative damage model are treated probabilistically. Model uncertainty is represented by the ratio between actual and calculated stresses, the latter obtained through finite element analysis. Annual response spectra for a fatigue-critical connection are developed through Monte Carlo simulation, which show that there is a continual and accelerating increase in the mean stress range experienced by the connection with time. S-N curves proposed in United States and United Kingdom codes are used in combination with Miner’s rule, to estimate the remaining fatigue life of the connection for different target failure probabilities. Parametric studies revealed that fatigue life estimates exhibit the highest sensitivity to detail classification, to S-N predictions in the region of high endurances, and to model uncertainty. This highlights the importance of field monitoring for old bridges approaching the end of their useful life.     

Fatigue Behavior of Carbon Fiber Reinforced Polymer-Strengthened Reinforced Concrete Bridge Girders

This study examines the effects of one-dimensional fiber-reinforced polymer (FRP) composite rehabilitation systems on the flexural fatigue performance of reinforced concrete bridge girders. Eight 508?mm deep and 5.6?m long reinforced concrete T-beams, with and without bonded FRP reinforcement on their tensile surfaces, were tested with a concentrated load at midspan under constant amplitude cyclic loading. The objective of this investigation is to establish the effect that these repair systems have on the fatigue behavior and remaining life of the girders. Results indicate that the fatigue behavior of such retrofit beams is controlled by the fatigue behavior of the reinforcing steel. The fatigue life of a reinforced concrete beam can be increased by the application of an FRP retrofit, which relieves some of the stress carried by the steel. The observed increase in fatigue life, however, is limited by the quality of the bond between the carbon FRP and concrete substrate. Debonding, initiating at midspan and progressing to a support, is common and is driven partially by the crack distribution and shear deformations of the beam.     

Behavior of Structural Composite Lumber T-Beam Bridge Girders after Fatigue Loading

Recent innovation in the engineered wood industry has produced structural composite lumber (SCL) that achieves excellent strength, stiffness, and efficient use of wood. Product variations of SCL, such as laminated veneer lumber (LVL) and parallel strand lumber (PSL), are currently being used in transportation to produce bridge girders and decks for rural and other low traffic volume roads. Although the elastic and shear properties of SCL are available, no attempt has been made to estimate the fatigue performance of bridge girders. This study tested 12 new and 2 old, weathered SCL T-beam bridge girders with material and preservative variations for AASHTO-specified flexural fatigue under a stress-controlled test setup simulating 60?years of service. Transverse posttension was applied to the girders simulating a real-life situation. Results from the study indicate that the girders are capable of withstanding the repetitive loads without much physical damage. A few of the LVL girders had severe delamination at the SCL-epoxy interface. The fatigued girders were loaded statically up to failure and compared with the ultimate flexural strength of fresh girders. The girders did not show any appreciable strength loss because of one million cycles of fatigue loading. There was no effect of SCL type and preservative treatment on fatigue strength.     

Distributed Strain Measurement in Steel Bridge with Fiber Optic Sensors: Validation through Diagnostic Load Test

Fiber optic sensing technologies are emerging as valid alternatives for the health monitoring of civil structures. Distributed sensors based on Brillouin scattering add the unique capability of measuring strain and temperature profiles along optical fibers. Measurement is performed by establishing the correlation between fiber strain and temperature, and the frequency shift of the Brillouin backscattered light induced by a monochromatic light pulse. The technology holds potential for use on large structures and integrated transportation infrastructure. Its effectiveness has been assessed through scaled laboratory experiments, whereas field validation is limited to very few demonstration projects conducted to date. This paper presents a pilot application of Brillouin optical time domain reflectometry to measure strain profiles along the steel girders of a continuous slab-on-girder bridge subjected to diagnostic load testing. One of the exterior continuous girders required heat-straightening after falling during construction due to wind. The significance of applying a distributed measurement technique lies in the potential to assess the global girder response, which would be impractical and uneconomical using discrete measurement techniques. A 1.16?km long sensing circuit was installed onto the web of four girders. The circuit comprises bare optical fiber sensors, and a novel adhesively bonded fiberglass tape with embedded sensing fibers for strain measurement and thermal compensation. The strain profiles were first converted into deflection profiles and validated against discrete deflection measurements performed with a high-precision total station system. Structural assessment based on comparison of the strain profiles with the results of three-dimensional finite-element analysis of the bridge superstructure, and with specification mandated criteria, indicated that the response of the girder under investigation was within the design limits, and did not pose serviceability concerns. Factors that may affect measurement accuracy are finally discussed on the basis of the experimental and numerical results.     

Fatigue Strength of Trolley Bridge Stringers Made of ASTM A7 Steel

Nineteen S15×42 (in U.S. units) stringers from a trolley bridge made of ASTM A7 carbon steel were tested in constant-amplitude fatigue. The bridge was built in 1900 and was abandoned in 1958. In 1985, the stringers were removed from the bridge and were tested in the laboratory. The test results showed that uniform corrosion and pitting reduced the fatigue strength of the stringers from Category A to Category D. The fatigue strength was reduced more by pitting than by uniform corrosion.     

Variable-Amplitude Fatigue Strength of Structural Steel Bridge Details: Review and Simplified Model

This paper reviews eight previous studies on the variable-amplitude (VA) fatigue strength of structural steel details: (1) four studies in the finite-life regime in which the number of cycles to failure of the specimens are equal to or shorter than the number of cycles at the intersection between the sloped S-N line and the VA fatigue limit, hereafter called the transition life; and (2) four studies in the infinite-life regime that is, at numbers of cycles greater than the transition life. The VA data correlate well with the constant-amplitude data when the former are plotted in terms of an equivalent root-mean-cube stress range. The effects of the following variables on the fatigue strength of structural details are discussed: block sequence in a stress range spectrum, spectrum size, type of spectrum, minimum stress, and type of steel. A so-called long-life factor quantifies how far a type of detail was cycled into the finite-life regime. Based on the results of the literature review, the writers recommend that the current AASHTO log-log bilinear equations for calculating the fatigue life be replaced with a single equation similar to the equation for predicting the fatigue crack growth rate in metals. This simplified model more accurately predicts the fatigue life near the VA fatigue limit.     

High-Cycle Fatigue of Diagonally Cracked Reinforced Concrete Bridge Girders: Field Tests

Large numbers of conventionally reinforced concrete deck–girder (RCDG) bridges remain in-service in the national highway system. Diagonal cracks have been identified in many of these bridges, which are exposed to millions of load cycles during service life. The anticipated life of these bridges in the cracked condition under repeated service loads is uncertain. RCDG bridges with diagonal cracks were inspected and instrumented. Strain and crack displacement data were collected under ambient traffic conditions and controlled test trucks. Results indicated relatively small stirrup stresses and diagonal cracks exhibited opening and closing under truck loading.     

Investigation of Large Web Fractures of Welded Steel Plate Girder Bridge

Constructed in 1972 with ASTM A36 (250 MPa) steel, a highway bridge in Maryland is comprised of seven welded steel plate girders of a constant web depth of 2,286 mm (90 in.). In March 2003, the web fractures of two steel girders were discovered in a three-span continuous superstructure unit. A full-height web fracture occurred in an interior girder at a cross frame connection plate; and a partial-height web fracture occurred in an exterior girder at an intermediate transverse stiffener next to a cross frame. The investigation of the girder fractures involved fracture surface examination, material testing, fracture mechanics analysis, and comprehensive finite-element modeling for fracture driving forces. The fracture mechanics analysis indicated that a brittle web fracture could occur at a high stress level with either a surface crack or a through-thickness crack of certain dimensions. Finite-element analysis using a global model and submodels investigated three possible causes: (1) localized distortion of the unsupported web gap due to the lateral forces of cross frame members; (2) fabrication induced out-of-flatness of the web plate under in-plane loading; and (3) residual stresses at the fracture origin area due to the stiffener-to-web welds. The investigation concluded that one or a combination of these can result in the high local tensile stresses triggering a brittle web fracture with certain crack dimensions at the fracture origin area. Several retrofit concepts were investigated for their effectiveness in reducing stresses in the fracture origin area. Bridge inspections in the subsequent 6 years after the web fractures have not reported any other cracks in the bridge.     

Implementation of a Long-Term Bridge Weigh-In-Motion System for a Steel Girder Bridge in the Interstate Highway System

This technical paper discusses the implementation of a long-term bridge weigh-in-motion system for use in determining gross vehicle weights of trucks crossing steel girder bridges. The system uses strain data to determine truck weights using an existing structural health monitoring system installed on a interstate highway bridge. The applied system has the advantage of not using any axle detectors in the roadway; and instead all analyses are performed using strain gauges attached directly to the steel girders, providing for a long-term monitoring system with minimal maintenance. Long-term data has been used to demonstrate that this method can be readily applied to gain important information on the quantity and weights of the trucks crossing the highway bridge.