Monitoring Steel Girder Stability for Safer Bridge Erection

The collapse of the State Route 69 Bridge over the Tennessee River near Clifton, Tennessee, is an example of how instability and lateral torsional buckling failure of a single steel bridge girder during erection might cause collapse of the whole steel superstructure. Close attention should be given to the stability of steel plate girders during erection when the lateral support provided to the compression flange might temporarily not be present. Rules of thumb in use today have been adopted by contractors/subcontractors to check the stability of cantilever or simply supported girders under erection using the L/b ratio, where L is the unbraced length and b is the compression flange width. For each girder section, a maximum L/b ratio exists beyond which lateral torsional buckling failure would occur under girder self-weight. Parametric studies were conducted following the latest AASHTO LRFD code in order to indentify the maximum L/b ratio for various girder sections and check the rules of thumb, as well as determine the dominating section parameters on girder stability under erection. Advanced nonlinear finite-element analyses were also conducted on a girder section for both the cantilever and the simply supported case in order to further understand the behavior of girder instability due to lateral torsional buckling under the self-weight, as well as to develop a trial-and-error methodology for identifying the maximum L/b ratio using computer analysis. At the same time, the effect of lateral bracing location on the cantilever free end has been investigated, and it turned out that bracing the top tension flange would be more effective to prevent lateral torsional buckling than bracing the bottom compression flange.     

Verification of Incremental Launching Construction Safety for the Ilsun Bridge, the World’s Longest and Widest Prestressed Concrete Box Girder with Corrugated Steel Web Section

The Ilsun Bridge is the world’s longest (801?m in total length) and widest (30.9?m in maximum width) prestressed concrete box girder bridge incorporating a corrugated steel web. This bridge has fourteen spans, twelve of which were erected using an incremental launching method, a method that is rarely applied in this type of bridge. To verify the construction safety of the Ilsun Bridge, this investigation focuses on the span-to-depth ratio, buckling shear stress of the corrugated steel webs, optimization of the length of the steel launching nose, detailed construction stage analysis, and the stress level endured by the corrugated steel webs during the launching process. The span-to-depth ratio of the Ilsun Bridge was found to be well-designed, using a conservative corrugated steel web design. Further, our investigation revealed that the conventional nose-deck interaction equation was not suitable for corrugated steel web bridges. As a result, a detailed construction stage analysis and measurements of this bridge was performed to examine stress levels and ensure safety during the erection process. The results revealed that there are essential design issues that should be considered when designing prestressed concrete box girder bridges with corrugated steel webs and that, when constructing them, the incremental launching method should be used.     

Erection Procedure Effects on Deformations and Stresses in a Large-Radius, Horizontally Curved, I-Girder Bridge

Special attention is required in the construction of horizontally curved steel I-girder bridges due to coupled effects of primary bending and torsional forces. Misguided steel erection procedures can lead to undesired stresses, deflections, and rotations in these types of bridges, resulting in a structure with misaligned geometry and in an unknown state of stress. Further complicating the issue, little guidance related to curved bridge behavior during construction is provided by current design codes, leaving contractors and designers uncertain as to the most appropriate steps to take to achieve an efficient, safe structure. A horizontally curved, six-span steel I-girder bridge located in central Pennsylvania that experienced severe geometric misalignments and fit-up complications during steel erection was studied to investigate curved girder behavior during construction. The structure was monitored during corrective procedures intended to realign it with the design geometry, and field data used to calibrate a three-dimensional computer model generated via SAP2000. The techniques and assumptions proven in the calibration process were used to create a numerical model of a three-span continuous portion of the bridge, which was the subject of several analyses exploring the effects erection sequencing, implementation of upper lateral bracing, and use of temporary supports had on the final deformed shape of the curved superstructure. Findings indicated that using paired girder erection produced smaller radial and vertical deformations than single girder techniques for this structure, and that the use of lateral bracing between the fascia and adjacent interior girders and the placement of temporary shoring towers at span quarter points are both effective means of further reducing levels of deflection.     

Construction of a Horizontally Curved Steel I-Girder Bridge. Part II: Inconsistent Detailing

The erection of horizontally curved steel I-girder bridges tends to be more complex than the erection of straight steel I-girder bridges. The erection of a curved steel I-girder bridge can be further complicated when the cross-frame members and girders are detailed inconsistently in an effort to force bridge components into some desirable geometric condition. Inconsistent detailing involves the intentional specification of cross-frame members that are either too long or too short to align with girder connector plates properly so as to force the girders into a given position, resulting in connection misalignments that must be resolved by applying external forces to the bridge components. The current research investigates the erection of a recently constructed horizontally curved steel I-girder bridge and highlights the fact that practice of inconsistent detailing can lead to very formidable and costly fit-up problems in the field; especially when girder sizes are large.     

Lateral Stiffness of Steel Bridge I-Girders Braced by Metal Deck Forms

The lateral-torsional buckling capacity of steel bridge girders is often increased by incorporating bracing along the girder length. Permanent metal deck forms (PMDF) that are used to support the wet concrete deck during bridge construction are a likely source of stability bracing; however, their bracing performance is greatly limited by flexibility in the connections currently used with the formwork. This paper outlines results from a research study that assessed and improved the bracing potential of metal deck forms used in bridge applications. The research study included shear tests of PMDF panels, and also lateral displacement and buckling tests of twin girder systems braced with PMDF. This paper will provide key results from the shear panel tests and then focus on the lateral displacement tests. Parametric investigations of PMDF bracing behavior were conducted using finite-element analyses and the results from the lateral displacement tests served a critical role in calibrating the finite element models. This paper documents key results from lateral load tests of 17 girder–PMDF systems using a variety of bracing details and PMDF thickness values.     

Feasibility of a 1,400 m Span Steel Cable-Stayed Bridge

This paper describes the feasibility of 1,400 m steel cable-stayed bridges from both structural and economic viewpoints. Because the weight of a steel girder strongly affects the total cost of the bridge, the writers present a procedure to obtain a minimum weight for a girder that ensures safety against static and dynamic instabilities. For static instability, elastoplastic, finite-displacement analysis under in-plane load and elastic, finite-displacement analysis under displacement-dependent wind load are conducted; for dynamic instability, multimodal flutter analysis is carried out. It is shown that static critical wind velocity of lateral torsional buckling governs the dimension of the girder. Finally, the writers briefly compare a cable-stayed bridge with suspension bridge alternatives.     

Stability of Slender Webs of Prestressed Concrete Box-Girder Bridges

Long-span, prestressed concrete, box-girder bridges are haunched and have a span-to-depth ratio of 15 to 20 at the piers. This leads to slender webs, particularly for bridges built with high performance concrete. For girders with sloped webs and constant bottom slab width, the web plate is normally warped, which leads to web curvature in the direction of the principal compressive stresses. It is first shown that buckling is not critical as long as the web is uncracked. But, if the webs have shear cracks, the slenderness ratio of the diagonal compression struts can be very high so that the moments and stability of the curved struts need to be studied. It is shown that the tensile forces in the stirrups—determined according to the truss analogy—will counteract the lateral deformations of the slender compression struts. The procedure, which was developed for the design of the Confederation Bridge in Eastern Canada, will be illustrated by applying it to the slender webs of that bridge.     

Composite Action and Adhesive Bond between Fiber-Reinforced Polymer Bridge Decks and Main Girders

This paper describes the behavior of hybrid girders consisting of fiber-reinforced polymer (FRP) bridge decks adhesively connected to steel main girders. Two large-scale girders were experimentally investigated at the serviceability and ultimate limit state as well as at failure. One of the girders was additionally fatigue loaded to 10 million cycles. Compared to the behavior of a reference steel girder, deflections of the two girders at the SLS were decreased by 30% and failure loads increased by 56% due to full composite action in the adhesive layer. A ductile failure mode occurred: Deck compression failure during yielding of the steel girder. The adhesive connections were able to prevent buckling of the yielding top steel flanges. Thus, compared to the reference steel girder, the maximum deflections at failure could be increased up to 130%. No deterioration due to fatigue loading was observed. Based on the experimental results, a conceptual design method for bonded FRP/steel girders was developed. The proposed method is based on the well-established design method for hybrid girders with concrete decks and shear stud connections. The necessary modifications are proposed.     

Large Shear Studs for Composite Action in Steel Bridge Girders

Shear studs used in composite steel bridge construction are typically 19.1 mm (? in.) or 22.2 mm (? in.) in diameter. This paper presents the development and implementation of the 31.8 mm (1??in.) stud diameter. Because the 31.8 mm (1??in.) stud has about twice the strength and a higher fatigue capacity than the 22.2 mm (? in.) stud, fewer studs are required along the length of the steel girder. This would increase bridge construction speed and future deck replacement, and reduce the possibility of damage to the studs and girder top flange during deck removal. Studs also can be placed in one row only, over the web centerline, freeing up most of the top flange width and improving safety conditions for field workers. This paper provides information on the development, welding, quality control, and testing of the 31.8 mm (1??in.) stud. Information on the first bridge built in the state of Nebraska with the 31.8 mm (1??in.) studs is provided.     

Experimental and Analytical Studies of a Horizontally Curved Steel I-Girder Bridge during Erection

A series of studies on an experimental, full-scale curved steel bridge structure during erection are discussed. The work was part of the Federal Highway Administration’s curved steel bridge research project (CSBRP). The CSBRP is intended to improve the understanding of curved bridge behavior and to develop more rational design guidelines. The main purpose of the studies reported herein was to assess the capability of analytical tools for predicting response during erection. Nine erection studies, examining six different framing plans, are presented. The framing plans are not necessarily representative of curved bridge subassemblies as they would be erected in the field; however, they represent a variety of conditions that would test the robustness of analysis tools and assess the importance of erection sequence on initial stresses in a curved girder bridge. The simply supported, three I-girder system used for the tests is described and methods for reducing and examining the data are discussed. Comparisons between experimental and analytical results demonstrate that analysis tools can predict loads and deformations during construction. Comparison to the V-load method indicates that it predicts stresses in exterior girders well, but can underpredict them for interior girders.     

Experimental Study on Moment–Plastic Rotation Capacity of Hybrid Beams

The moment–inelastic rotation behavior of hybrid steel girder bridges is experimentally investigated. Six welded girders having compact flanges and webs are statically loaded under three-point bending condition in order to simulate the interior pier section of a two-span continuous girder. Six girders, three with hybrid sections and three with homogeneous sections, are designed with three types of web slenderness ratios, resulting in three pairs of hybrid and homogeneous girders. The inelastic rotation capacities obtained from the experimental tests are then compared between hybrid and homogeneous girders. In addition, the results are compared with the prediction moment–inelastic rotation curve proposed in 1998 by White and Barth. It is concluded that, under the condition in this study, hybrid girders have more deformation capacity than homogeneous girders, and that the prediction curve is more conservative for a specimen with higher web slenderness ratio.     

Curved Steel I-Girder Bridge Response during Construction Loading: Effects of Web Plumbness

Horizontally curved steel I-girder bridge systems tend to deflect and rotate out of plane under the action of gravity. Oftentimes, this response will lead to a condition wherein the subsequent girder cross-sectional orientation is one where the web is out of plumb. Currently, there exists little guidance concerning what effect this web out of plumbness has on structural performance. As a result of this lack of guidance from design specifications, there is tendency within current practice to work to alleviate the out of plumb condition through various detailing and erection strategies, since the performance implications of its presence within the structure are poorly understood. The present research employs nonlinear finite-element modeling strategies to study the various effects that web out of plumbness has on flange tip stresses, vertical and lateral deflections, cross-sectional distortion, and cross-frame demands. The focus of the present work is the construction stage, and thus steel dead load is the governing loading condition treated. Web out of plumbness magnitudes of up to 5° are considered.     

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.     

Torsional Design of Hybrid Concrete Box Girders

Hybrid concrete box-girder bridges that include prestressed slabs and corrugated steel webs provide a major improvement over traditional prestressed concrete box-girder bridges. To reduce the self-weight, high strength concrete is used for the top and bottom slabs and corrugated steel webs are employed for the webs. Because the weight of the girders has been reduced, the span length can be increased for more cost-effective design. A series of systematic tests on hybrid concrete box girders subjected to torsion has been performed. According to the test results, an analytical model was developed. Using the developed analytical model, a step-by-step procedure for torsional design of such bridges is presented in this article. Based on the design procedure proposed, a girder is designed by the analytical model and checked to satisfy structural codes.     

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.     

Effective Bond Length of Carbon-Fiber-Reinforced Polymer Strips Bonded to Fatigued Steel Bridge I-Girders

After years in service, many steel girders have deteriorated to the point where fatigue cracks have initiated in the girders. In girders having cover plates that do not terminate in a compression region, a common type of crack initiates at the weld toe at the ends of the cover plate after being subjected to cyclic tensile loads due to traffic. The use of precured carbon-fiber-reinforced polymer (CFRP) laminates, adhered to the inside face of the girder tension flange, is one proposed method for repairing these cracked bridge girders. The main advantages of using CFRP laminates are their light weight and their durability, which result in ease of handling and maintenance. For the application of this rehabilitation method, it is important to determine the effective bond length for CFRP laminates adhered to the inside face of a cracked steel girder flange. Experimental tests using a new type of effective bond length test specimen were conducted in this research on several types of adhesives and precured CFRP laminates, in addition to several different bonding configurations. The minimum bond length required to achieve the maximum strength of the rehabilitation scheme for the materials investigated in this research was determined. The experimental results also indicated that an adhesive with relatively large ductility is required to redistribute the stresses successfully within the adhesive layer during increased loading. A simple analytical solution for the shear strain distribution in the adhesive layer was proposed for estimating the effective bond length, and the results were verified with computational analyses. Good agreement was found among the computational, analytical, and experimental results.     

Moment-Inelastic Rotation Behavior of Longitudinally Stiffened Beams

The significance for inelastic design of moment-inelastic rotation behavior with respect to interior pier sections of steel girder bridges is experimentally investigated. Under center span loading conditions, 12 welded, built-up, simply supported beams with various slenderness ratios of the flange and web plates are tested. In this test, lengths and locations for partial longitudinal stiffeners on the web plates are varied, and the results are then compared with the inelastic deformation capacity of beams without longitudinally stiffened web plates. The results are also compared with the inelastic design code in AASHTO LRFD bridge design specifications. It is concluded that (1) the ultimate strength of stiffened beams is governed by the local buckling at the compression flange of the far end from the loading point due to the presence of a partial longitudinal stiffener; and (2) the inelastic rotation capacity and ultimate strength of a beam with a stiffened web plate are remarkably improved. The optimum length and location of stiffeners on the plates are given.     

Influence of Early Temperature Rise on Movements and Stress Development in Concrete Decks

The primary focus of this paper is to develop an understanding of temperature changes introduced by hydration heat release in the first few hours after casting in the thermal movements and stresses of the concrete deck and girders. Temperature and strain measurements from a simply supported, single-span, steel girder bridge with a composite concrete deck are presented. It is shown that setting occurs during the temperature rise and partial strain compatibility between steel girder and concrete deck is initiated at the end of the concrete temperature rise. Full strain compatibility between concrete deck and steel girder is achieved at the end of the cooling period following the initial temperature rise. The stresses in the steel girder associated with temperature changes are interpreted using an analytical model. It is shown that the concrete deck gains sufficient stiffness at the end of the temperature rise to restrain the movement of the top flange. Concrete deck movement in the period associated with cooling following the initial temperature rise is restrained, which could potentially produce tensile stress in concrete. The magnitude of tensile stress at the end of the cooling period depends upon the difference in the temperatures of the concrete deck and top flange and on the temperature gradient in the steel girder at the end of the heating period.     

Girder Differential Deflection and Distortion-Induced Fatigue in Skewed Steel Bridges

The prevalence of fatigue cracking in steel bridge girders due to out-of-plane web distortion motivates development of procedures to evaluate the effects of distortional fatigue. In a previous study sponsored by the Minnesota Department of Transportation (Mn/DOT) the frequency and magnitude of distortional stresses on a typical skewed, steel bridge with staggered, bent-plate diaphragms were assessed. The results revealed a diaphragm deformation mechanism that causes distortional fatigue in the girder web gap, leading to simple, accurate estimates of fatigue stress if bridge properties and differential vertical deflection between girders are known. In the present study, linear finite element models are used to represent composite steel bridges and identify bridge parameters that influence relative deflection of adjacent girders. Parameters found to have a significant effect on differential deflection include girder spacing, angle of skew, span length, and deck thickness. These results are incorporated in a simple procedure that is intended for use in management schemes for skewed, steel-girder bridges, with staggered, bent-plate diaphragms, susceptible to web gap distortional fatigue.