Structural Performance and Field Applications of High Durable, Light Weight Composite Bridge Deck
Structural Performance and Field Applications of High Durable, Light Weight Composite Bridge Deck
Structural Performance and Field Applications of High Durable, Light Weight Composite Bridge Deck
4. Port Maitenance and Information System in Korea Inspection and Maitenance System
Recent days composite bridge deck is considered one of the promising alternative to concrete
bridge deck due to many advantages. In this paper, structural performance of glass fiber
reinforced composite bridge deck for DB24 truck load of 3-cell trapezoidal profile, called
‘Delta Deck’, fabricated with pultrusion is presented. Extensive experiments including
flexural tests, fatigue tests, and field load tests for the pultruded deck were conducted. Some
field applications of developed composite deck are presented as well. IFinite element analysis
also performed and the results weralso proposes the next generation deck profile for vertical
snap-fit connections.
isteel and concrete des such as light weearch and development, appr the compost eck and and
analytical studies on the glass reinforced compost dgeicted with vacuung and
pultrusionscribel field t uced. In additgram for oncecoe are pres
KEYWORDS: glass fiber, fiber-reinforced composites, bridge composite deck, fiber-
reinforced composites, structural tests, analysis, field applications
1. INTRODUCTION
To cope with problems of deterioration and corrosion of conventional steel and concrete
materials, high durable, lightweight fiber reinforced composites are considered one of the
promising alternative construction materials for the civil infrastructures.Ialong with field
application-antro results ivolved in the devecks are described in the paper. Vacuum bag
molding, filament winding and pultrusion were incorporated for the fabrication of the deck.
Finite element analysis and various experiments were carried out for these decks.
axial-flexural tests, field di and proceor develament winding are pres
Due to considerable advantages of composite bridge deck, many studies were carried out and
increasing field applications were reported recently1),2). recently1),2). Composite bridge deck is
considered to have significant advantages compared with conventional concrete deck. Since it
is high durable, corrosion-free material, much longer service life and lower maintenance cost
is expected so that LCC(life cycle cost) can be much lower. Due to light weight
characteristics, it can save dead load as much as 80% compared with conventional concrete
deck and much slender substructures can be possible. When it is used for redecking, load
carrying capacity of the bridge is upgraded automatically without strengthening girder or
substructures. Due to fast installation it reduces construction period and traffic block time
significantly during the construction, considerable savings of direct and indirect costs are
1
Dean/College of Engineering, Professor/Dept. of Civil & Env. Eng., Kookmin University, eoul, Korea
(email: [email protected]) Deo
2
Deputy Manager, Kookmin Composite Infrastructure Inc., Seoul, Korea(email: [email protected])
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Research Associate, Kookmin University, Seoul, Korea(email: [email protected]) University, Korea, A
4
Inc., Korea, PresidentPhD candidate
1
possible. Some recent research results along with field applications for the composite bridge
decks are described in the following.
2
403
70 333
CS M (Ra n d o m )
o o o
DB T ( 9 0 / +4 5 / - 4 5 )
200
o
R o vin g ( 0 )
o o
LT ( 0 / 9 0 )
Fig. 1 Profile of pultruded deck (Delta Deck) Fig. 2 Laminate design of top flange
Finite element analysis was performed to examine serviceability and structural safety of the
‘Delta-Deck’ applied to the steel plate girder bridge. Deflection, stresses and failure indices of
the composite deck were checked, including buckling stability for the web due to DB24 truck
load. Figure 4 shows cross section of the bridge under consideration. The bridge in
consideration is 30m in length with simple supports and has 5 girders of 2.5m spacing. FE
analysis was carried out for this bridge using the material properties of composites obtained
by micromechanics. After verification by analysis, the deck was fabricated with pultrusion.
Then FE analysis was performed again using the actual material properties obtained from
coupon tests of the fabricated deck. In this paper, analysis results for the later case were
described. Figure 5 shows deflection contours after analysis.
Impact factor of 0.3 was applied to the live load. Two lane load model was considered in its
transverse direction. A serviceability criterion of deflection was taken L/425. Tsai-Wu failure
theory was adopted to examine the structural safety of the composite deck herein. The results
of analysis are tabulated in Table 1. As shown in the table, the designed composite deck
satisfies all the requirements of serviceability and structural safety. Photo 1 shows fabrication
process for the pultrusion and Photo 2 shows completed section after fabrication.
are .
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Composite Deck
Girder
Fig. 4 Cross section of bridge model for analysis Fig. 5 Deflection contours after analysis
Photo 1 Fabrication process for the pultrusion Photo 2 Completed section after fabrication
According to the analysis, compressive stresses σx=-143.5 kgf/cm2, σy=-160 kgf/cm2 occur at
the upper deck where the load is applied and tensile stress σx=-177.0 kgf/cm2, σy=73.4 kgf/cm2
at the lower deck. Compared with maximum failure strength (table 2) obtained through
specimen tests, both upper and lower deck have safety factors between 10 and 18 (table 2).
According to Tsai-Wu failure analysis, failure index at the upper deck is 0.096, meaning that
the deck has safety factor of 10.42. When the web is checked for buckling, due to its
eigenvalue of 14.22 and knock-down factor of 0.75, it has the safety factor of 10.67. The
results for safety factors of stresses, deflections and failure indices are arrangedanalysis are
tabulated in table 1. As is manifest from shown in the table, the designed composite deck
satisfieds all the requirements of serviceability and structural safety. Material properties used
in the analysis are from results of specimen test for the deck (table 3).
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It is common that created stresses be compared with allowable ones. However, when the
stress field exists under 2 axes or multi-axes condition, appropriate failure theory needs to be
applied in order to check the safety of structural members. For isotropic materials such as
steel, maximum shear stress theory or strain energy theory is often used. However, for
composite material, which is neither isotropic nor yielding, existing failure theory does not
hold. Tsai-Wu failure theory iswas adopted to examine the structural safety of the composite
deck herein.
3. TESTS FOR EVALUATION OF STRUCTURAL PERFORMANCE
3 point flexural test was carried out in order to evaluate the structural performance of the
pultruded composite deck. At failure load, flexural capacity and deflection of the deck were
evaluated. Load was applied on the wheel load contact area of 580mm x 230mm. Test deck
was 2.25m long, 1.0m wide and was simply supported. The load was applied at the center of
the span. Photo 3 shows figures of the flexural test.
Vertical deflections of the deck was measured through LVDTs positioned at 3 locations in the
transverse direction at the middle of the span. Strains were measured at 16 points on the top
and bottom flange of the deck. Figure 6 shows the locations of strain gages attached to the
deck. L signifies longitudinal direction and T signifies transverse direction of the test deck.
Photo 3 Flexural test for pultruded composite deck Fig. 6 Location of the strain gages attached to
top and bottom flanges
tubes
At failure,
maximumthis was 411.9kN and maximum vdisplacemn was 35.6mm. Load-dispshows load-
deflection curves. Since the rear axle load of DB24 including impact factor 1.3, is 122.4kN,
factor of safety becomes 3.36 (411.9/122.4). However, if the effect of wheel load distribution
for 1.0m width is considered, it can be expected to have more safety margin. Photo 9 shows
local punching failure on the loaded pae of the deck occurring at the momenioad.
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considered, it is expected to have more margins. FE analysis was also carried out for the test
deck model. Though it is not included in the paper, the analytical results agreed well with
those from experiments3). In the analysis, Tsai-Wu failure index was also evaluated for the
failure load of 411.9kN. Figure 9 shows the distribution of failure indices according to Tsai-
Wu failure analysis. Tsai-Wu failure indices for each strain gage location are shown in Table 3.
450 450
400 400
350 350
300 300
Load (kN)
Load (kN)
Fig. 7 Load-deflection curve Fig. 8 Load-strain curve for top flange in L direction
Table 3 shows results of the specimen test for the composite deck, which are used as input data for FE analysis.
composite deck for FE Analysis
k
6
ovement)Y : transverse to tube direction (parallel to vehicle
movement) failure dex
7
As shown in Table 3,
nalytical result with the result from flexural performance test. Tsai-Wu failure analysis is
performed for the maximum failure load, 42tonf. mMaximum failure index at the partload
location of upper decktop flange of loading turned out to beis 0.41. This means1 so that the
composite deck iswas still safe analyticallyis not at the failure status under the load,
42tonf411.9kN. Considering this, fFlexural failure iswasis expectanticipated to occur at
102ton00.3kNf, which iswas 2.44 times 42tonf, meaning that the composite deck hads much
larger flexural capacity.
A shearPush-down test wais carried out for the shear connection part between the girder and
the composite deck. Test specimen was made in such a way that tto evaluate allowable shear
force of the shear connector. Variables considered weare: diameter of shear connector,
compressive strength of mortar, and thickness of bedding. Connection part between the girder
and the composite deck to be tested wais fabricated with shear connectors and non-shrinkage
mortar with bedding thickness of 20mm. The test wais performed by applying forces to the
steel girder which wais connected to the lower flanges of the composite deck. wo deck panels
with 4 shear connectors were connected to the H-type girder in each side. Shear pockets
weare formed at two places per each deck andfilled with non-shrinkage mortar was injected to
complete the composite partgirder-deck connection. Four studs weare installed with its
interval being 33cm. 0, strain gages are a
Photo 3 Shear Test for Deck-Girder ConnectionTest ResultAccording to the test result,
iInterlaminar shear failure occurreds at the joint of the web and lower bottom
flange of the composite deck at the load of, 56tonf49.2kN. The shear
connectors were wasis already yielded when the failure of the composite deck
occurreds at the joint. Allowable Sshear force at failure can be estimated based
on the average yield strength of 4 shear connectors. Photo 5 shows shear test
set-up for deck-girder connection. Fig. 21ure 10 shows load-strain curves
measured from the strain gages attached to the shear connectors.
Compression fatigue test was carried out to evaluate fatigue characteristics of composite deck
at girder support. 2million cycles of repetitive load corresponding to DB24 wheel load of
122.4kN including impact was loaded with 5Hz over the tire contact area of 23.0cmx57.7cm.
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600
500
400
300
200
100
0
-2000 -1000 0 1000 2000 3000
Photo 5 Shear test for deck-girder connection Fig. 10 Load-strain curves for shear connectors
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and the diameter 22mm for the shear connectors. According to design manuals for Korean
highway bridges, allowable shear force becomes 2.9tonf and yield shear force becomes
10.9tonf, which is yield stress multiplied by the cross section area of shear connector. Safety
factor of 4.0 is to be applied even though 3.7 is obtained through computation. According to
the design manual, yielding of shear connector is to occur at the strain 0.2%. On the safe side,
computation is based on the shear force (Fig. 21) measured at the yield strain (εy=
σy/Es=2,400/2,040,000=0.0012). ear force per shear connector is approximately 11.9tonf
when yielding occurs (εy=0.0012).ording to the yield strength criteria given in table 5.
4 shear connectors)
[tonf]
a
5. Structural Performance Test for connecting parts
between composite deck and guard wall
5.1 Test Summary
deck, anardized drawing in the specification.
Performance test for the guard wall is carried out
by loading the upper part of the guard wall at the
rate of 2mm/min under strain control. 2 and Fig.
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Photo 4 Performance Test for connecting parts
n compe de
바닥판 상부면
평면도
바닥판
P3
P1 P2 (T)
(T) (T)
주형
9 방호벽
Strain gage(L)
Strain gage(T)
LVDT
Photo 6 Compression fatigue test Fig. 11 Strain gage location for test deck
1 - BG1 2 - BG2
3 - BG3 4 - BG4
5 - BG5 6 - BG6
7 - BG7 8 - BG8
9 - BG9 10 - BG10
11 - BG11 12 - BG12
13 - BG13 14 - BG14
15 - BG15 16 - BG16
17 - BG17 18 - BG18
19 - BG19 20 - BG20
21 - BG21 22 - BG22
23 - BG23 24 - BG24
25 - BG25 26 - BG26
Photo 6 shows test set-up for compression fatigue test. Figure 11 shows strain gage location
for the test deck.
After 2 million cycle loading,
After the repetitive loading of initial, 0.5million, 1million, 1.5million, and 2million cycles,
static load test wais carried out. From the LVDT attached to the deck interior, relative
displacements of upper and lower flange weare read: 0.88mm at initial stage, converging from
1.13mm to 1.25mm until 2million cycles. According to strain gages it wais found that after 1
million cycles, increasing rate of strain sloweds down as number of cycles increaseds so that
overall fatigue behavior of the deck gotets stabilized.
anyrenot observedic load tests wereas carMultipMaximua1cf 13 shows load-strain relats at
gage 6 obtained from static load tests after loading of each cycle measuhown in the figure,
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sStrain after 2 million cycles of repetitive loading does t change too much compared with
those of the initial deck. The strains got very mized after 0.5million cycles, thus it is
demonstrated that composite deck at girder location showed satisfactory fatigue
characteristics(Sung Cmaring the strains at each gage location, maximum was found at gage 6.
The stress corresponding to this maximum strain after 2million cycles of loading was only
1/13.1 of the ultimate strength of the deck. Thus it can be concluded that the deck is
sufficiently safe as far as fatigue is concerned.
tf . sh-up for flexurafatigue tesows stran gage location at bottange of the test dibutad of 7.8
tonf is ready for test deck of 1m width (Sunpart inside the deck panel. Photo 612 shows
flexural fatigue test and figure 16 shows strain gage location at bottom flange of the deck..
140 90
80
120
70
100
60
Load(kN)
80
Load (kN)
50
60 40
0 c y c le 0 c y c le
30
40 500,000 c yc le s 5 0 0 , 0 0 0 c y c le s
20
1,000,000 c yc le s 1 , 0 0 0 , 0 0 0 c y c le s
20 10 1 , 5 0 0 , 0 0 0 c y c le s
1,500,000 c yc le s
2,000,000 c yc le s 0
2 , 0 0 0 , 0 0 0 c y c le s
0
0 200 400 600 800
0 100 200 300 400 500 600 700
S t ra i n ( μ ε ) S tr a in( μ ε )
middl left)
After 2million cycles of repetitive loading, any type of damage for the deck at the center span
and girder location was not observed. Also at the deck and girder connection, any crack or
damage of the non-shrinkage mortar, which was filled around shear studs in the pocket of the
deck was not found. Figure 14 shows load-strain curves at gage BG7. As shown in the figure,
curves for each load cycle were almost identical. Thus it demonstrated that the deck possesses
excellent flexural fatigue characteristics.
After extensive structural performance tests in the laboratory as described above, developed
pultruded deck was installed on the demonstration bridge of plate girder type at lane
enlargement project of Gyongbu highway. For this demonstration bridge, field load test was
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carried out as shown in Photo 8. Maximum deck deflection was measured 1.92mm for the test
truck. Permissible deflection for the 2.0m girder spacing was estimated 4.7mm when
deflection serviceability criterion of L/425(2000/425) was applied. Thus the safety margin of
2.4 was obtained for this test truck. When test truck load was converted to DB24 truck load,
serviceability safety margin can be estimated to 2.9. For the maximum stress obtained from
measured strain at the bottom flange of the deck in the direction of bridge axis, factor of
safety was evaluated as 39 compared with ultimate strength of the deck for the equivalent
DB24 truck load. From field load test, it is demonstrated that developed pultruded deck
possesses sufficient margin for deflection serviceability and strength.
Several field applications of ‘Delta Deck’ composite bridge deck are now underway in Korea.
Photo 9 shows installation of filament wound composite deck over another demonstration
Fig. 26 shows load-strain relationship measured from BG 7 attached in the transverse
direction to the vehicle movement or longitudinal direction of the deck tubes.
Photo 8 Field load test for demonstration bridge Photo 9 Installation of filament wound
composite deck
Photo 10 Installation of composite deck Photo 11 Heavy loaded traffic over composite
at Gwangyang deck bridge at Gwangyang
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Photo 12 Installation of composite Photo 13 Installation of composite
deck at Jangsoo(I) deck at Jangsoo(II)
13
plate girder bridge at Gwangju. After field verification for the previous two demonstration
composite girder bridges, 150m-long, 12m-wide pultruded composite deck plate girder bridge
was constructed at Gwangyang in October, 2004. Photo 10 shows installation of composite
deck at Gwangyang bridge. Photo 11 shows heavily loaded traffic over the completed bridge
at Gwangyang. As an another case, Photo 12 and 13 show installation of 25m-long, 12m-wide
pultruded composite deck steel plate girder bridge at Jangsoo in October, 2004. Photo 14 and
15 show other case of installation of 70m-long, 12m-wide pultruded composite deck PSC
girder bridge at Pyungtaek in November 2004. Photo 16 and 17 show 45m-long, 9m-wide
pultruded composite deck arch bridge at Seoul in June, 2004. In addition to above, several
more composite deck bridges are expected to be constructed in 2005. After successful
implementation of composite bridge deck, a large project of 300m-long and 35m-wide wharf
type girder bridge in Busan new port area is currently under design and planned to be installed
in 2006.
Finite element analysis was carried out to verify strength and serviceability criteria for the
designed deck. Simply supported plate girder bridge of 30 m span of 5 girders with 2.5m
spacing was considered. Analysis was performed with COSMOS/M for the finite element
meshes with SHELL4L element for the composite deck and girders. At the location of load,
refined meshes were incorporated. DB24 truck load was applied for the analysis and the
deflection contours are shown in Fig. 13 after analysis. From the analysis results, designed
deck is considered to possess factor of safety of 2.53 for deflection(L/425 criteria), 10.4 for
Tsai-Wu failure criteria and 10.7 for web buckling for the DB24 truck load.
Fig. 14. Pultrusion process of deck fabrication Fig. 1
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AND TESTED UNDER UNI-AXIAL COMPRESSION, BENDING, AND
AECHANICAL AND GEOMETRICAL PROPERTIES, CONSTRUCT P-M
DIAGRAMS THAT C2.
2. Ps 3a
P Capacity
u
m
–1
Gravity type(Fig. 4)
(Fig. 5 Fig. 6)
Suction pile foundation(Fig. 8
Japan- aseismic design,
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16
17
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