Experimental Study of UHPC Repair for Corrosion-Damaged Steel Girder Ends
Publication: Journal of Bridge Engineering
Volume 22, Issue 8
Abstract
Corrosion of girder ends is a prevalent problem that significantly reduces the bearing capacity of bridges. Current repair methods are expensive and difficult to implement. A novel repair method was developed for steel girder ends with corrosion damage using ultrahigh-performance concrete (UHPC) to encase the corrosion. For this repair, UHPC panels were attached to girders with shear studs welded to the web and flange surrounding the corroded area. This allowed shear and bearing forces to transfer from the girder to the UHPC panels. The UHPC panels provided a new load path, thereby increasing the bearing capacity of the girder. Half-scale experiments were conducted on undamaged, damaged, and repaired rolled steel girder specimens. The test results were used to (1) determine the decrease in bearing capacity attributable to section loss, (2) demonstrate the ability of the UHPC repair to restore lost girder capacity, and (3) investigate the constructability of the repair method. The experimental results show that the UHPC repair was easily implemented and succeeded in restoring bearing capacity lost as a result of corrosion damage.
Get full access to this article
View all available purchase options and get full access to this article.
Acknowledgments
This paper presents results from a study funded by the Connecticut Department of Transportation under Project SPR-2282. The authors thank the Connecticut Department of Transportation, especially John Henault, Timothy Fields, Richard Van Allen, Leo Fontaine, Kevin Mahoney, Bao Chuong, Rabih Barakat, Anne-Marie McDonnell, Bradley Overturf, and Richard Hanley, and the Department of Homeland Security for their support. The significant contribution of Michael Culmo of CME Associates in developing the concept is greatly appreciated. The authors thank John Gasparine of Infra-Metals, David Hunt of Berlin Steel, Joseph D’Agostino of Parsons Brinckerhoff, and Vic Perry, Dominique Corvez, John Ephraim, Gaston Doiron, and Andrew Ross of Lafarge for their generous donation of materials. The assistance of Peter Glaude and Jim Olney from the UConn School of Engineering machine shop is appreciated. Special thanks go to James Mahoney, Lori Judd, and Carolyn Ward of the Connecticut Transportation Institute. In addition, the assistance of Manish Roy, Masoud Mehr, Alicia Echevarria, Man Xu, Javier Duluc, Michael Humphreys, Amanda McBride, Alexandra Hain, Christopher Pawlowski, and Andy Dauphinais during the research project is appreciated.
References
Abbas, S., Nehdi, M. L., and Saleem, M. A. (2016). “Ultra-high performance concrete: Mechanical performance, durability, sustainability, and implementation challenges.” Int. J. Concr. Struct. Mater., 10(3), 271–295.
Ahn, J.-H., Kainuma, S., and Kim, I.-T. (2013a). “Shear failure behaviors of a web panel with local corrosion depending on web boundary conditions.” Thin Wall. Struct., 73, 302–317.
Ahn, J.-H., Kainuma, S., Yasuo, F., and Takehiro, I. (2013b). “Repair method and residual bearing strength evaluation of a locally corroded plate girder at support.” Eng. Fail. Anal., 33, 398–418.
Albrecht, P., and Hall, T. T., Jr. (2003). “Atmospheric corrosion resistance of structural steels.” J. Mater. Civ. Eng., 2–24.
ASCE. (2014). 2013 report card for America's infrastructure, Reston, VA.
Chang, L.-M., and Lee, Y.-J. (2001). “Evaluation and policy for bridge deck expansion joints.” FHWA/IN/JTRP-2000/1, Joint Transportation Research Program, Indiana Dept. of Transportation and Purdue Univ., West Lafayette, IN.
Classen, M., Gallwoszus, J., and Stark, A. (2016). “Anchorage of composite dowels in UHPC under fatigue loading.” Struct. Concr., 17(2), 183–193.
Close, J., and Miller, P. C. (2011). “Preliminary design report—Putnam Bridge, Bridge No. 00417. Project No. 53-175.” Technical Rep., Connecticut Dept. of Transportation, Newington, CT.
ConnDOT (Connecticut Dept. of Transportation). (1955). “Bridge No. 00352: Greenwich-Killingly Expressway Rt. 1 over Oil Mill Rd.” Technical Rep., Newington, CT.
ConnDOT (Connecticut Dept. of Transportation). (1962). “Bridge No. 03399D: Rt. 84 on ramp over parking lot,” Technical Rep., Newington, CT.
Elnashai, A. S., Takanashi, K., Elghazouli, A. Y., and Dowling, P. J. (1991). “Experimental behaviour of partially encased composite beam-columns under cyclic and dynamic.” Proc. Inst. Civ. Eng., 91(2), 259–272.
Feldmann, M., Hechler, O., and Hegger, J., and Rauscher, S. (2011). “Fatigue behavior of shear connectors in high performance concrete.” Proc., Int. Conf. on Composite Construction in Steel and Concrete 2008, ASCE, Reston, VA, 310–321.
FHWA (Federal Highway Administration). (2014). “Design and construction of field-cast UHPC connections.” FHWA-HRT-14-084, Washington, DC.
FLDOT (Florida Dept. of Transportation). (2011). “Section 6: Steel beam and girder repair.” Bridge maintenance and repair handbook, Tallahassee, FL, 78–83.
Graybeal, B. (2014). “Design and construction of feld-cast UHPC connections.” FHWA-HRT-14-084, Federal Highway Administration, Washington, DC.
Grünberg, J., Lohaus, L., Ertel, C., and Wefer, M. (2008). “Multi-axial and fatigue behavior of ultra-high performance concrete (UHPC).” Proc., 2nd Int. Symp. on Ultra-High Performance Concrete, Kassel University Press, Kassel, Germany, 485–491.
He, J., Liu, Y., Chen, A., and Yoda, T. (2012a). “Shear behavior of partially encased composite I-girder with corrugated steel web: Experimental study.” J. Constr. Steel Res., 77, 193–209.
He, J., Liu, Y., Lin, Z., Chen, A., and Yoda, T. (2012b). “Shear behavior of partially encased composite I-girder with corrugated steel web: Numerical study.” J. Constr. Steel Res., 79, 166–182.
Hyashi, K., Ono, S., and Nakamura, S. (2003). “Experimental studies on retrofit by partially encased concrete to the steel I-girder subjected to buckling deformation.” Technical Memorandum 3920, Public Works Research Institute, Tsukuba, Ibaraki, Japan, 229–236.
Kayser, J. R., and Nowak, A. S. (1989). “Capacity loss due to corrosion in steel-girder bridges.” J. Struct. Eng., 1525–1537.
Khurram, N., Sasaki, E., Katsuchi, H., and Yamada, H. (2014b). “Experimental and numerical evaluation of bearing capacity of steel plate girder affected by end panel corrosion.” Int. J. Steel Struct., 14(3), 659–676.
Khurram, N., Sasaki, E., Kihira, H., Katsuchi, H., and Yamada, H. (2014a). “Analytical demonstrations to assess residual bearing capacities of steel plate girder ends with stiffeners damaged by corrosion.” Struct. Infrastruct. Eng., 10(1), 69–79.
Koch, G. H., Brongers, M. P. H., Thompson, N. G., Virmani, Y. P., and Payer, J. H. (2002). “Corrosion cost and preventive strategies in the United States.” Rep. No. FHWA-RD-01-156, Turner-Fairbank Highway Researh Center, McLean, VA.
Kristoff, W. M. (2011). “In-depth inspection of Bridge No. 03399D: I-84 over parking lot, Hartford, CT.” Technical Rep., Connecticut Dept. of Transportation, Newington, CT.
Liu, C., Miyashita, T., and Nagai, M. (2011). “Analytical study on shear capacity of steel I-girders with local corrosion nearby supports.” Procedia Eng., 14, 2276–2284.
LS-DYNA 971 [Computer software]. Livermore Software Technology Corporation, Livermore, CA.
Miyashita, T., et al. (2015). “Repair method for corroded steel girder ends using CFRP sheet.” Proc., IABSE-JSCE Conf. on Advances in Bridge Engineering-III, International Association for Bridge and Structural Engineering, Zurich, Switzerland, 614–620.
Nakamura, S., Momiyama, Y., Hosaka, T., and Homma, K. (2002). “New technologies of steel/concrete composite bridges.” J. Constr. Steel Res., 58(1), 99–130.
Nakamura, S., and Narita, N. (2003). “Bending and shear strength of partially encased composite I-girders.” J. Constr. Steel Res., 59(12), 1435–1453.
Ogami, H., Fujii, K., Yamada, T., and Iwashaki, H. (2015). “Renovation of corroded girder end in plate girder bridge with resin and rebars.” Implementing innovative ideas in structural engineering and project management, S. Saha, Y. Zhang, S. Yazdani, and A. Singh, eds., ISEC, Fargo, ND, 1–6.
Reinhorn, A. M., and Bracci, J. (1992). “Multi-axis load cell design and construction.” Rep. No. NCEER-92-0027, National Center for Earthquake Engineering Research, Univ. of New York, Buffalo, NY.
Rossow, M. (2003). “FHWA bridge maintenance: Superstructure.” Bridge maintence training reference manual, Continuing Education and Development Engineering, Stony Point, NY.
Russell, H., and Graybeal, B. A. (2013). “Ultra-high performance concrete: A state-of-the-art report for the bridge community.” Rep. No. FHWA-HRT-13-060, Federal Highway Administration, McLean, VA.
Shaheen, E., and Shrive, N. (2008). Cyclic loading and fracture mechanics of ductal concrete, Springer Science & Business Media.
Shi, X., Fay, L., Yang, Z., Nguyen, T. A., and Liu, Y. (2009). “Corrosion of deicers to metals in transportation infrastructure: Introduction and recent developments.” Corros. Rev., 27(1–2), 23–52.
Usukura, M., Yamaguchi, T., Suzuki, Y., and Mitsugi, Y. (2013). “Strength evaluation for a corroded damaged steel girder end considering its collapse mechanism.” Proc., 13th East Asia-Pacific Conf. on Structural Engineering and Construction (EASEC-13), Hokkaido Univ. Collection of Scholarly and Academic Papers (HUSCAP), Sapporo, Hokkaido, Japan.
Van de Lindt, J. W., and Pei, S. (2006). “Buckling reliability of deteriorating steel beam ends.” Electron. J. Struct. Eng., (6), 1–7.
Wipf, T. J., Fanous, F. S., Klaiber, F. W., and Eapen, A. S. (2003). “Evaluation of appropriate maintenance, repair, and rehabilitation methods for Iowa bridges.” Iowa Dept. of Transportation Rep. No. TR-429, Dept. of Civil and Construction Engineering, Iowa State Univ., Des Moines, IA.
WisDOT (Wisconsin Dept. of Transportation). (2015). “Bridge rehabilitation.” Bridge manual, Madison, WI.
Yamaguchi, E., and Akagi, T. (2013). “Degradation of load-carrying capacity of steel I-girder end due to corrosion.” Proc., 13th East Asia-Pacific Conf. on Structural Engineering and Construction (EASEC-13). Hokkaido University Collection of Scholarly and Academic Papers (HUSCAP), Sapporo, Hokkaido, Japan.
Yaun, J., and Graybeal, B. A. (2014). “Bond behavior of reinforcing steel in ultra-high performance concrete.” FHWA Publication No. FHWA-HRT-14-090, Federal Highway Administration, Mclean, VA.
Zaghi, A. E., Wille, K., Zmetra, K., and McMullen, K. (2015). “Repair of steel beam/girder ends with ultra high strength concrete (phase I).” Rep. No. CT-2282-F-15-2, Dept. of Civil and Environmental Engineering, Univ. of Connecticut, Storrs, CT.
Zmetra, K. (2015). “Repair of corrosion damaged steel bridge girder ends by encasement in ultra-high performance concrete.” Ph.D. thesis., Dept. of Civil Engineering, Univ. of Connecticut, Storrs, CT.
Zmetra, K., Zaghi, A. E., and Wille, K. (2015). “Rehabilitation of steel bridge girders with corroded ends using ultra-high performance concrete.” Proc., Structures Congress 2015, ASCE, Reston, VA, 1411–1422.
Information & Authors
Information
Published In
Journal of Bridge Engineering
Volume 22 • Issue 8 • August 2017
Copyright
© 2017 American Society of Civil Engineers.
History
Received: Jul 12, 2016
Accepted: Feb 22, 2017
Published online: May 18, 2017
Published in print: Aug 1, 2017
Discussion open until: Oct 18, 2017
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.