Evaluation and Repair of Wrought Iron and Steel Structures in Indiana
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Final Report FHWA/IN/JTRP – 2004/4 Evaluation and Repair of Wrought Iron and Steel Structures in Indiana by Mark D. Bowman Professor of Civil Engineering and Amy M. Piskorowski Graduate Research Assistant School of Civil Engineering Purdue University Joint Transportation Research Program Project No: C-36-SGJJJ File No: 7-4-61 SPR-2655 Conducted in Cooperation with the Indiana Department of Transportation And the U.S. Department of Transportation Federal Highway Administration The contents of this report reflect the views of the authors who are responsible for the facts and accuracy of the data presented herein. The contents do not necessarily reflect the official view or policies of the Federal Highway Administration or the Indiana Department of Transportation. This report does not constitute a standard, specification, or regulation. Purdue University West Lafayette, Indiana June 2004 TECHNICAL REPORT STANDARD TITLE PAGE 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. FHWA/IN/JTRP-2004/4 4. Title and Subtitle 5. Report Date Evaluation and Repair of Wrought Iron and Steel Structures in Indiana June 2004 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Mark D. Bowman, Amy M. Piskorowski FHWA/IN/JTRP-2004/4 9. Performing Organization Name and Address 10. Work Unit No. Joint Transportation Research Program 1284 Civil Engineering Building Purdue University West Lafayette, IN 47907-1284 11. Contract or Grant No. SPR-2655 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Indiana Department of Transportation State Office Building Final Report 100 North Senate Avenue Indianapolis, IN 46204 14. Sponsoring Agency Code 15. Supplementary Notes Prepared in cooperation with the Indiana Department of Transportation and Federal Highway Administration. 16. Abstract Throughout the state of Indiana, there a number of older, historical bridges which have been in service since the late 19th century. Many, although not all, of these bridges are truss structures comprised either partially or completely of wrought iron members. Moreover, most of them need some degree pf maintenance or rehabilitation. However, engineers who must recommend repair or rehab operations typically do not know the material properties and behavior of wrought iron members. Consequently, an investigation was initiated to review and classify typical material properties of wrought iron members. This investigation involved three phases that included a literature review of other research and bridge rehabilitation studies, a survey of many transportation agencies throughout Indiana and the United States, and fundamental material and mechanical testing in the laboratory. Based upon this research, rehabilitation and repair recommendations for wrought iron members in existing bridges were then developed. 17. Key Words 18. Distribution Statement historic bridges, bridge rehabilitation, wrought iron, truss bridges, repair procedures, rehabilitation, welding. No restrictions. This document is available to the public through the National Technical Information Service, Springfield, VA 22161 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 242 Form DOT F 1700.7 (8-69) TECHNICAL Summary Technology Transfer and Project Implementation Information INDOT Research TRB Subject Code: 25-1 Bridges June 2004 Publication No.: FHWA/IN/JTRP-2004/4, SPR-2655 Final Report Evaluation and Repair of Wrought Iron and Steel Structures in Indiana Introduction Throughout the state of Indiana, there performance and repair of wrought iron bridge are numerous historical bridges that have been in structures, (2) initiate a database of sample material service since the late 19th century and need to be properties through data collection and experimental either rehabilitated or replaced. Since the funds testing, and (3) develop suggested repair techniques needed for replacement are often unattainable by for joints and members typical of wrought iron the agencies owning these bridges, and the bridge construction. demolition of these historically significant bridges Upon the completion of these would be detrimental to preserving the history of objectives, the historical properties of wrought iron the state, rehabilitation of these bridges is an option were more fully understood and some typical repair worth investigating. procedures for historical wrought iron bridge Among the historical bridges existing members were developed. The properties of in Indiana, many are older metal bridge structures wrought iron were determined both by collecting comprised either partially or completely of wrought data from previous studies and by performing iron that need to be repaired or rehabilitated. Due experimental testing with wrought iron materials to technological advances in material production from two different wrought iron bridges in Indiana. during the late 19th century, the use of wrought iron The repair procedures were also developed from diminished, along with a common knowledge of experimental testing and analysis of literary wrought iron material properties and behavior. research. When rehabilitating these bridges engineers often The scope of the research completed in this have a difficult time determining not only if the study consisted of a literature review / synthesis metal is wrought iron, but also what material study, a survey of state Departments of properties to utilize when designing repairs. This Transportation and County Engineers, materials makes the repair and rehabilitation process testing of historical wrought iron, analysis and extremely difficult. evaluation of existing repair procedures and the This research study involved three primary development of repair recommendations. objectives: (1) collect information related to the Findings In the literature review completed, properties were discovered and the data were an in-depth search of many databases was recorded. completed along with an in-depth search of A survey was distributed to State collections in the Purdue University library Departments of Transportation, State Local system, and many other library systems. In this Technical Assistance Programs, Indiana County search, articles dealing with the repair and Engineers, and other engineering consultants to rehabilitation of specific bridges were located determine the number of existing historic iron along with many articles dealing with the material bridges in service in other locations and to collect properties and manufacturing processes of any existing wrought iron repair procedures used wrought iron. Also, many historic sources by other agencies. The results from this survey containing test data on wrought iron material did not lead to any existing wrought iron bridge 25-1 06/04 JTRP-2004/4 INDOT Division of Research West Lafayette, IN 47906 member repair procedures, but it did lead to a impact testing, and fatigue testing helped to better understanding of the need for more determine many common material properties. knowledge concerning the behavior of historic Eyebar end connection testing lead to a better wrought iron. understanding of the load distribution and force Material and mechanical testing was transfer behavior for one particular bridge completed on wrought iron bridge members from member connection. two existing bridges in Indiana. This testing Testing was also performed on different included: micrographs, chemical analysis, types of repairs that might be typically utilized in hardness testing, tensile coupon testing, charpy the field. These repairs included: member impact testing, tensile testing of eyebar end straightening with heat, straightening without connection, and some limited fatigue testing. The heat, welding to join two members, and filler micrographs that were taken helped to develop a welding to restore section loss from corrosion. better understanding of the microstructure of the This testing, along with articles found in the metal. The chemical analysis completed lead to a literature search, helped lead to the development determination of particular elements that are of some procedures and suggestions that could be commonly found in historic wrought iron. used to repair historic wrought iron bridge Hardness testing, tensile coupon testing, charpy members. Implementation Upon completion of this research study, capacity of the bridge, it is recommended that recommendations were developed to aid in the they be replaced with a stronger material. inspection and rehabilitation of existing historic truss bridges consisting of wrought iron tension 4. Upon inspecting an existing historic members. wrought iron truss bridge, it is not uncommon to find severe corrosion near the joints of the 1. When inspecting an old, existing bridge bridge. The eyebars and diagonals should be it is important to know the type of materials for checked thoroughly for section loss from the bridge members. For bridges consisting of corrosion. If severe section loss has occurred the wrought iron members, it is helpful to determine engineer should consider either replacement or the year and manufacturer of the bridge. A repair of the member. Repair of a corroded visual inspection of the surface of the material member could involve one of two procedures. after it has been thoroughly cleaned can be used One option is to grind the corroded areas to to aid in determining if the material is wrought clean metal and then use a filler weld repair