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BRIDGE GIRDER ALTERNATIVES for EXTREMELY AGGRESSIVE ENVIRONMENTS Florida Department of Transportation – BDV22-977-01

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BRIDGE GIRDER ALTERNATIVES for EXTREMELY AGGRESSIVE ENVIRONMENTS Florida Department of Transportation – BDV22-977-01 Final Report BRIDGE GIRDER ALTERNATIVES FOR EXTREMELY AGGRESSIVE ENVIRONMENTS Florida Department of Transportation – BDV22-977-01 Prepared by: Dr. Jeff Brown, Civil Engineering Dr. Daewon Kim, Aerospace Engineering Dr. Ali Tamijani, Aerospace Engineering Graduate Research Assistants: Vasileios Papapetrou Abdellah Azeez Satyagajen Arunasalam Rajenthiran Embry-Riddle Aeronautical University Daytona Beach, FL January 2018 Embry Riddle Aeronautical University BDV22-977-01 Disclaimer The opinions, findings, and conclusions expressed in this publication are those of the author(s) and not necessarily those of the Florida Department of Transportation or the U.S. Department of Transportation. ii Embry Riddle Aeronautical University BDV22-977-01 Metric Conversion Chart SYMBOL WHEN YOU KNOW MULTIPLY BY TO FIND SYMBOL LENGTH in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km mil 1/1000th of an inch 0.025 millimeters mm AREA in2 square inches 645.2 square millimeters mm2 ft2 square feet 0.093 square meters m2 yd2 square yards 0.836 square meters m2 ac acres 0.405 hectares ha mi2 square miles 2.59 square kilometers km2 VOLUME fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft3 cubic feet 0.028 cubic meters m3 yd3 cubic yards 0.765 cubic meters m3 NOTE: volumes greater than 1000 L shall be shown in m3 MASS oz ounces 28.35 grams g Ib pounds 0.454 kilograms kg T short tons (2000 Ib) 0.907 metric ton Mg (or “t”) TEMPERATURE (exact degrees) °F Fahrenheit Celsius °C ILLUMINATION fc foot-candles 10.76 lux Ix fl foot-lamberts 3.426 candela/m2 cd/m2 FORCE and PRESSURE or STRESS kip 1000 pound force 4.45 kilonewtons kN Ibf pound force 4.45 newtons N Ibf/in2 pound force per square 6.89 kilopascals kPa inch ksi kip per square inch 6.89 megapascals MPa ksf kip per square foot 47.88 kilopascals kPa Msi million pounds per 6.89 gigapascals GPa square inch iii Embry Riddle Aeronautical University BDV22-977-01 SYMBOL WHEN YOU KNOW MULTIPLY BY TO FIND SYMBOL LENGTH mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi AREA mm2 square millimeters 0.0016 square inches in2 m2 square meters 10.764 square feet ft2 m2 square meters 1.195 square yards yd2 ha hectares 2.47 acres ac km2 square kilometers 0.386 square miles mi2 VOLUME mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m3 cubic meters 35.314 cubic feet ft3 m3 cubic meters 1.307 cubic yards yd3 MASS g grams 0.035 ounces oz kg kilograms 2.202 pounds Ib Mg (or “t”) megagrams (or “metric 1.103 short tons (2000 Ib) T TEMPERATURE (exact degrees) °C Celsius 1.8C+32 Fahrenheit °F ILLUMINATION Ix lux 0.0929 foot-candles fc cd/m2 candela/m2 0.2919 foot-lamberts fl FORCE and PRESSURE or STRESS kN kilonewtons 0.225 1000 pound force kip N newtons 0.225 pound force Ibf kPa kilopascals 0.145 pound force per Ibf/in2 square inch iv Embry Riddle Aeronautical University BDV22-977-01 Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient Catalog No. 4 Title and Subtitle 5 Report Date Bridge Girder Alternatives for Extremely Aggressive Environments January 2018 6 Performing Organization Code 7. Author(s) 8 Performing Organization Report Jeff R. Brown, Daewon Kim, Ali Tamijani, and Vasileios Papapetrou No. 9 Performing Organization Name and Address 10 Work Unit No. (TRAIS) Embry-Riddle Aeronautical University 600 S. Clyde Morris Blvd. 11 Contract or Grant No. Daytona Beach, FL 32114 BDV22-977-01 12 Sponsoring Agency Name and Address 13 Type of Report and Period Florida Department of Transportation Covered Research Center, MS 30 Final Report 605 Suwannee St June 2015-January 2018 Tallahassee, FL 32399-0450 14 Sponsoring Agency Code 15 Supplementary Notes 16 Abstract The primary objective of this study was to identify viable alternatives for fiber-reinforced polymer (FRP) bridge girders and evaluate their potential for use in extremely aggressive environments in Florida. The first phase of the study included a comprehensive survey of in-service FRP-girder bridges in the U.S. along with several projects in Europe. Four distinct girder types were identified ((1) pultruded sections, (2) U-girders, (3) concrete-filled FRP tubes, and (4) Hillman Composite Beams (HCBs)) and the current status of existing bridges for each type was verified. Fiber-reinforced polymer flat-panel slab bridges were also investigated. Three general girder geometries were chosen for further investigation and evaluation: (1) hybrid FRP/concrete-filled U-girder, (2) hybrid FRP/concrete-filled tube, and a (3) pultruded double-web I- beam (DWB). Tthe required amount of FRP material and associated manufacturing costs were determined for a range of span lengths between 30 ft and 75 ft. All three options were assumed to develop full composite action with an 8-in-thick cast-in-place reinforced concrete deck. The number of girders per span was also treated as a variable. Two unique design methodologies were investigated for the FRP U-girders. The first method relied on AASHTO distribution factors to determine the single-girder structural demand. The second method involved finite element analysis of the entire bridge combined with structural optimization techniques to determine the most efficient girder geometry. The CFFTs were exclusively using the AASHTO distribution factor method, and the DWB alternative was evaluated using finite element analysis. Results indicate that the hybrid FRP/concrete U-girder is the most efficient and cost-effective alternative. The girder cost per square foot for the U-girder alternative ranges from just over $40 per square foot of bridge deck for a 30-ft span to $140 per square foot for the 75-ft span. These estimates include the costs for materials and manufacturing of the FRP U-girder and the cast-in-place concrete required to fill the girder on-site. Additional costs associated with placing the girders and the cast-in-place reinforced concrete deck are not included. 17 Key Words 18 Distribution Statement Fiber-reinforced polymer composites, bridge girders, No restrictions. This document is extremely aggressive environments available to the public through the National Technical Information Service, Springfield, Virginia 22161 19 Security Classification 20 Security Classification 21 No. of pages 22 Price (of this report) (of this page) 283 Unclassified Unclassified v Embry Riddle Aeronautical University BDV22-977-01 Acknowledgements The authors would like to thank Mr. Will Potter, PE, from the Florida DOT Structures Research Center, and Mr. Rick Vallier, PE, and Mr. Steve Nolan, PE, from the Florida DOT Structures Design Office, for their insight and thoughtful review of the work described in this final report. We would also like to thank Mr. Stanislav Sykulskyi for his contributions in the early phase of this study. vi Embry Riddle Aeronautical University BDV22-977-01 Executive Summary There are four primary objectives in the current study: 1. Investigate the performance of previously implemented fiber-reinforced polymer (FRP) vehicle bridges and FRP bridge girders. 2. Identify three viable, non-proprietary, bridge girder alternatives for further analysis and development for use in extremely aggressive environments. 3. Evaluate and apply existing design criteria as described in AASHTO LRFD-7 and LRFD-FRP for each alternative for simply supported bridge spans ranging from 30 ft to 75 ft. 4. Perform a comprehensive alternatives analysis which considers cost, design methodology, materials, manufacturing, constructability, maintenance, and service life. A total of five vehicle bridges in the U.S. were identified that utilize all-FRP girders as the primary flexural element to resist shear and bending along the span length. Two bridges in Virginia, constructed in 1997 and 2001, rely on pultruded double-web I-beams (DWBs) produced by the Strongwell Corporation to support a laminated timber deck with an asphalt overlay. The first bridge spans 18 ft and uses 8-in-deep DWBs spaced at 12 in on center. The second bridge spans 39 ft and uses 36-in-deep DWBs spaced at 42 in on center. The Texas DOT completed two demonstration bridges in 2005 and 2007 that utilize glass FRP U-girders with span lengths of 30 ft (x two spans) and 50 ft, respectively. Both of these bridges incorporated a cast-in-place reinforced concrete deck with cast-in-place barriers. Finally, the Kings Stormwater Channel bridge near the Salton Sea in California utilized concrete-filled FRP tubes (CFFTs) to support a pultruded FRP bridge deck. This bridge was completed in 2001 and then replaced in 2013 due to durability concerns with the FRP bridge deck. The CFFT girders did not present any maintenance or durability concerns during 12 years of service. Three different FRP manufacturing methods were identified as potentially viable for FRP bridge girders in the current study: (1) vacuum-assisted resin transfer molding (VARTM)/vacuum infusion processing (VIP), (2) pultrusion, and (3) filament winding. VARTM/VIP allows the greatest flexibility with regards to U-shaped girder dimensions and laminate architecture (i.e., thickness and fiber orientation angle). The primary disadvantage associated with VARTM/VIP is that producing an individual girder is labor intensive. Pultrusion is a highly mechanized process that is capable of producing high volumes of structural shapes, but a major disadvantage is the high cost of tooling required for a specific girder geometry. Another disadvantage is that the fiber orientation angle is constrained to the primary axis direction of the girder. Some off-axis strength can be obtained, but this is usually limited.
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