Repair of Cracked Aluminum Overhead Sign Structures with Glass Fiber Reinforced Polymer Composites

Transportation departments have been using aluminum overhead sign structures since the 1950s. It is well documented that cracks develop in the welds between diagonal and chord members due to fatigue stresses from wind-induced vibration of the slender members. The cracks propagate to complete failure of the members, which can cause collapse of the truss and inflict injuries. The original design of overhead sign structures did not consider fatigue as a limit state. In addition, field welding of aluminum structures for any possible repairs is prohibited. A repair method for the cracked aluminum welded connections between diagonals and chord members using glass fiber reinforced polymer composites (GFRPs) is proposed. The static load carrying capacity of the welded connection, and the cracked connection repaired with GFRP composites are established. The paper describes the surface preparation of the aluminum tubular members, and the architecture and application sequence of the GFRP composite to retrofit the connection. Experimental results are presented from static tests of welded aluminum connections, welded aluminum connections retrofitted with GFRP composites, and new aluminum connections that depend only on GFRP composite elements for their strength. The results from monotonic static tests carried out on cracked welded specimens from actual sign structures show that the retrofitted connection with GFRP reinforcement achieved 1.17 to 1.25 times the capacity of the welded aluminum connection without any visible cracks. This result, and the minimal traffic disruption anticipated in the actual field application, makes this retrofit method a good candidate for implementation.