Hale Boggs Cable Stayed Bridge Inspection, Fatigue Analysis & Repair
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1 Hale Boggs Cable Stayed Bridge Inspection, Fatigue Analysis & Repair Paul Norton, PE Principal & National Bridge Practice Leader TranSystems - Boston Office Jian Huang, PE, Ph.D. Master Professional TranSystems - Ft. Lauderdale Office
2 Hale Boggs Cable Stayed Bridge Inspection, Fatigue Analysis & Repair Paul Norton Part I Introduction Inspection findings Scope of work Jian Huang Part II Fatigue evaluation procedure and specifications 3-D structural analysis Fatigue stress ranges Remaining mean/safe fatigue lives Conclusions and recommendations Repair plans 2
3 Location of Hale Boggs Bridge Interstate I-310 over the Mississippi River between Destrehan and Luling. Also known as the Luling Bridge. 3
4 Hale Boggs Cable Stayed Bridge Bridge open to traffic in Oct The third major cable stayed bridge in the United States The first cable stayed bridge added to the interstate highway system 4
5 Hale Boggs Cable Stayed Bridge Weathering steel towers and superstructure Orthotropic deck (first in cable stayed bridges in US) 5
6 Plan and Elevation of the Bridge 2, , The main river crossing is a cable stayed bridge having a total length of 2,732 ft. 6
7 Cross Section of the Bridge 10 Shoulder 4.25 Shoulder 12 Lane 12 Lane 2-Steel tub girders connected with floor beams and diaphragms 82 ft bridge width 7
8 Problem Statement Major Rehabilitation Project $28M Replacement of All Cables Our recent bridge inspection found: Cracks occurred in the deck plate and the fillet weld at the connection of the box girder web transverse stiffener to the orthotropic deck (112 cracks out of 800+ total locations). Cracks exhibited only in the outboard web of the box girders (under the outside wheel line of traffic in each direction). Cracks in other components (lifting lugs & cross girder) 8
9 Crack in orthotropic deck plate at end of transverse stiffener weld Crack Crack Location 75 Cracks in Orthotropic Deck Plate 37 Cracks in Weld Only Transverse Stiffener 9
10 Crack in orthotropic deck rib at Lifting Lug Crack 13 Cracks in Orthotropic Deck Rib 10
11 Crack inside cross girder at internal diaphragm Crack 3 Cracks in Cross Girders 11
12 Crack Locations West = 4, 27, 27, 15, 5 East = 0, 3, 16, 10, 5 12
13 Crack Locations 13
14 Crack Location Crack Location 14
15 Scope of Work Determine the stress levels in the problematic area Perform a fatigue evaluation of the critical area Calculate the remaining mean fatigue and safe fatigue lives of the critical details Develop the repair plans 15
16 Fatigue Evaluation Procedure and Specifications The fatigue analysis was performed in accordance with AASHTO Guide Specifications for Fatigue Evaluation of Existing Steel Bridges, 1990 with interims through 1995 NCHRP 299, Fatigue Evaluation Procedures for Steel Bridges 16
17 3-D Structural Analysis Model Modeling features: SAP2000 program Modeling: Longitudinal segment, Transverse half section Shell elements Refined shell element size, max. 1 x1 mesh in the area of interest Edge constraint between intersecting shell elements Boundary joints at the centerline of the bridge: free but fixed rotation about the bridge direction Boundary joints at ends of the analyzed segment: fixed translations and free rotations 17
18 General View of the 3-D Analysis Model Refined mesh Web of Box Girder Floor beam Deck 18
19 Fatigue Truck Loading Outside Lane Inside Lane Applied Wheel Loads: One truck (outside lane or inside lane) kips x 1.1 (impact assumed) = 13.2 kips wheels spaced at 6 feet transversely Applied as area load 19
20 Analytical Results: Outside Lane Loaded Concentrated stress at the web transverse stiffener to the deck plate connection (outer web). Concentrated stress 20
21 Fatigue Stress Ranges in Deck Plates Table 1 Fatigue Stress Ranges in Deck Plates Along Outer Web of Box Girder Location Outside Web AASHTO Limiting Stress Range (Cat. C) (Axial, ksi) (ksi) At Web Stiffener At Non Web Stiffener Table 2 Fatigue Stress Ranges in Deck Plates Along Inner Web of Box Girder Location Inner Web AASHTO Limiting Stress Range (Cat. C) (Axial, ksi) (ksi) At Web Stiffener At Non Web Stiffener
22 Fatigue Stress in Web Stiffeners At outer Web At inner web 6.6 ksi 1.2 ksi 22
23 Fatigue Stress Ranges in Web Stiffeners Table 3 Fatigue Stress Ranges in Web Transverse Stiffener to Deck Connection at Outer Web Location Outside Web AASHTO Limiting Stress Range (Cat. C) (Vertical, ksi) (ksi) Corner at Crack Corner Closer to Box Girder Web Table 4 Fatigue Stress Ranges in Web Transverse Stiffener to Deck Connection at Inner Web Location Inside Web AASHTO Limiting Stress Range (Cat. C) (Vertical, ksi) (ksi) Corner at Crack Corner Closer to Box Girder Web
24 Check for Infinite Safe Fatigue Life (if fatigue is an issue) Factored fatigue stress range AASHTO Limiting stress range (Cat. C) At outer web locations: 9.0 ksi vs. 4.4 ksi At inner web locations: 1.6 ksi vs. 4.4 ksi Outboard web locations will crack, 75 locations have already cracked. 24
25 Remaining Safe Fatigue Life and Mean Fatigue Life Safe Fatigue Life vs. Mean Fatigue Life: Safe/Mean = 1/2 Remaining Fatigue Life at outer web locations: Mean fatigue life: -8.8 years Safe fatigue life: years (negative means exceeded its fatigue life) Remaining Fatigue Life at inner web locations: Infinite 25
26 Repair Scheme Development No repair action Consider restricting traffic from the right travel lanes Fatigue cracking on the inside detail would not occur for 15 years Monitor detail on a more frequent basis (say every 12 months) 2-in diameter arrest holes in the deck plate Separation of the web transverse stiffener from the deck plate Combined repair schemes 26
27 Analytical Results if No Repair Action A 5-in long crack modeled (typical cracking found). 3.2 ksi at tip of crack Crack 3.6 ksi at tip of crack The deck stresses redistributed and decreased, but not enough. The stress ranges implies further crack may occur. 4.5 ksi at stiffener (crack location) Stiffener location 2.1 ksi at stiffener edge near web 27
28 2-in Diameter Arresting Holes Two 2-in diameter holes. Crack 2 Hole (typ.) The stress range at crack decreased by 54%. All stress ranges less than 4.4 ksi. 2.0 ksi at stiffener (crack location) 2.2 ksi at stiffener edge near web 28
29 2-in Diameter Arresting Holes and Cutting Web Stiffener The web transverse stiffener to deck connection removed. 7 Radius Circular Cut The stresses in the deck significantly reduced. 0.4 ksi at stiffener (crack location) 0.9 ksi at the drilled hole 0.9 ksi at the drilled hole 0.4 ksi at stiffener edge near web 29
30 Cutting Web Stiffener at Locations with No Cracking The web transverse stiffener to deck connection removed. 0.4 ksi at stiffener edge (vs. 6.6 ksi) The stresses in the deck significantly reduced. Web Stiffener location 0.6 ksi at stiffener edge near web 30
31 Fatigue Stress Ranges Vs. Repair Schemes 3-D Models/Repair Schemes At Crack Initiation Stiffener Edge Near Web Tip of Crack/Hole Web at Stiffener Location (ksi) (ksi) (ksi) (ksi) As Built Condition N/A in Crack Occurred in Crack + 2-in Ø Arrest Holes in Crack + 2-in Ø Arrest Holes + Cutting Stiffener As Built Condition + Cutting Stiffener N/A
32 Repair Plans: Drilled Patterns 32
33 Repair Plans: Cutting Transverse Stiffeners 33
34 Acknowledgement Owner of the Bridge: Louisiana DOT & Development CTL prime consultant for design & inspection IBT prime consultant for construction management TranSystems subconsultant to CTL & IBT 34
35 Thank you and any questions? Paul Norton, P.E., TranSystems, Boston, MA Jian Huang, Ph.D., P.E., TranSystems, Ft. Lauderdale, FL 35
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