IMAGE PROCESSING, ANALYSIS, AND MANAGEMENT TOOLS FOR GUSSET PLATE CONNECTIONS IN STEEL TRUSS BRIDGES Final Report PROJECT TPF-5(259) IMAGE PROCESSING, ANALYSIS, AND MANAGEMENT TOOLS FOR GUSSET PLATE CONNECTIONS IN STEEL TRUSS BRIDGES Final Report PROJECT TPF-5(259) by Christopher Higgins, Ph.D., P.E. Daniel Gillins, Ph.D., P.L.S. Michael Scott, Ph.D. Sinisa Todorovic, Ph.D. Farid Javadnejad Shravya Varakantham for Oregon Department of Transportation Research Section 555 13th Street NE, Suite 1 Salem OR 97301 and Federal Highway Administration 400 Seventh Street, SW Washington, DC 20590-0003 and The Departments of Transportation of California, Idaho, New York, North Carolina, Texas and Wisconsin October 2016 Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. FHWA-OR-RD-17-01 4. Title and Subtitle 5. Report Date Image Processing, Analysis, and Management Tools for Gusset Plate October 2016 Connections in Steel Truss Bridges 6. Performing Organization Code 7. Author(s) 8. Performing Organization Christopher Higgins, Daniel Gillins, Michael Scott, Sinisa Report No. Todorovic, Farid Javadnejad, Shravya Varakantham TPF-5(259) 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Oregon State University School of Civil and Construction Engineering 11. Contract or Grant No. 101 Kearney Hall Corvallis, OR 97331-3212 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Transportation Pooled Fund Program: Lead State: Final Report Oregon Dept. of Transportation 14. Sponsoring Agency Code Research Section and Federal Highway Admin. th 555 13 Street NE, Suite 1 400 Seventh Street, SW Salem, OR 97301 Washington, DC 20590-0003 and: The Departments of Transportation of California, Idaho, New York, North Carolina, Texas and Wisconsin 15. Supplementary Notes 16. Abstract This report details the research undertaken and software tools that were developed that enable digital images of gusset plates to be converted into orthophotos, establish physical dimensions, collect geometric information from them, and conduct specification-based and nonlinear finite element analyses of the connections. A software package, GussetImageProcessing.jar, was written that allows the user to process the images, remove the perspective, establish scale, identify the gusset plate boundaries, identify and group fasteners to truss members, and collect the geometric information to conduct AASHTO-LRFR connection ratings on the processed digital images. A separate software package, zGusset.tcl, uses the open-source program OpenSees as the analysis engine and is used to perform non-linear finite element analysis of a gusset plate model. To organize and query the collection of large numbers of high-fidelity quantitative images, a new approach was developed using Geographic Information System (GIS) to link images spatially across various geometric scales, temporally across inspection intervals, and to associate relevant metadata to the image view. 17. Key Words 18. Distribution Statement Gusset Plate, Steel Truss Bridge, Image Processing, finite Copies available from NTIS, and online at element analysis, Geographic Information System http://www.oregon.gov/ODOT/TD/TP_RES/ 19. Security Classification 20. Security Classification 21. No. of Pages 22. Price (of this report) (of this page) 119 Unclassified Unclassified Technical Report Form DOT F 1700.7 (8-72) Reproduction of completed page authorized Printed on recycled paper i ii SI* (MODERN METRIC) CONVERSION FACTORS APPROXIMATE CONVERSIONS TO SI UNITS APPROXIMATE CONVERSIONS FROM SI UNITS When You Multiply When You Multiply Symbol To Find Symbol Symbol To Find Symbol Know By Know By LENGTH LENGTH in inches 25.4 millimeters mm mm millimeters 0.039 inches in ft feet 0.305 meters m m meters 3.28 feet ft yd yards 0.914 meters m m meters 1.09 yards yd mi miles 1.61 kilometers km km kilometers 0.621 miles mi AREA AREA millimeters millimeters in2 square inches 645.2 mm2 mm2 0.0016 square inches in2 squared squared ft2 square feet 0.093 meters squared m2 m2 meters squared 10.764 square feet ft2 yd2 square yards 0.836 meters squared m2 m2 meters squared 1.196 square yards yd2 ac acres 0.405 hectares ha ha hectares 2.47 acres ac iii kilometers kilometers mi2 square miles 2.59 km2 km2 0.386 square miles mi2 squared squared VOLUME VOLUME fl oz fluid ounces 29.57 milliliters ml ml milliliters 0.034 fluid ounces fl oz gal gallons 3.785 liters L L liters 0.264 gallons gal ft3 cubic feet 0.028 meters cubed m3 m3 meters cubed 35.315 cubic feet ft3 yd3 cubic yards 0.765 meters cubed m3 m3 meters cubed 1.308 cubic yards yd3 NOTE: Volumes greater than 1000 L shall be shown in m3. MASS MASS oz ounces 28.35 grams g g grams 0.035 ounces oz lb pounds 0.454 kilograms kg kg kilograms 2.205 pounds lb short tons (2000 T 0.907 megagrams Mg Mg megagrams 1.102 short tons (2000 lb) T lb) TEMPERATURE (exact) TEMPERATURE (exact) (F- 1.8C+3 °F Fahrenheit Celsius °C °C Celsius Fahrenheit °F 32)/1.8 2 *SI is the symbol for the International System of Measurement iv ACKNOWLEDGEMENTS This research was funded through a pooled fund study led by the Oregon Department of Transportation. Contributors to the research funding were Federal Highway Administration, Wisconsin DOT, Idaho Transportation Department, Caltrans, Texas DOT, North Carolina DOT, and New York DOT. This support is gratefully acknowledged. DISCLAIMER This document is disseminated under the sponsorship of the Oregon Department of Transportation and the United States Department of Transportation in the interest of information exchange. The State of Oregon and the United States Government assume no liability of its contents or use thereof. The contents of this report reflect the view of the authors who are solely responsible for the facts and accuracy of the material presented. The contents do not necessarily reflect the official views of the Oregon Department of Transportation or the United States Department of Transportation. The State of Oregon and the United States Government do not endorse products of manufacturers. Trademarks or manufacturers’ names appear herein only because they are considered essential to the object of this document. This report does not constitute a standard, specification, or regulation. v vi TABLE OF CONTENTS GENERAL INTRODUCTION AND ORGANIZATION OF REPORT ................................. 1 PART 1: IMAGE PROCESSING FOR GUSSET PLATES 1.0 INTRODUCTION AND BACKGROUND ..................................................................... 5 2.0 METHODOLOGY ........................................................................................................... 7 2.1 ERROR ESTIMATION OF MEASUREMENTS .......................................................................... 8 3.0 IMPLEMENTATION .................................................................................................... 11 3.1 SOFTWARE TOOL OVERVIEW – GUSSET PLATE IMAGE PROCESSING TOOL (GPIPT) ............ 11 3.2 TASK 1 – TARGET DETECTION AND PERSPECTIVE REMOVAL ........................................... 12 3.2.1 Problem Statement – Target Detection and Perspective Removal ....................................................... 12 3.2.2 Literature Review – Target Detection and Perspective Removal ........................................................ 12 3.2.2.1 Template Matching Using Normalized Cross Correlation .............................................................................. 12 3.2.2.2 Normalized Cross-Correlation ........................................................................................................................ 13 3.2.3 Solution Approach – Target Detection and Perspective Removal ....................................................... 14 3.2.4 Challenges – Target Detection and Perspective Removal ................................................................... 16 3.2.4.1 Fasteners are Detected as Target Control Points ............................................................................................. 16 3.2.4.2 Extreme Precision Needed .............................................................................................................................. 16 3.3 TASK 2 – BOUNDARY DETECTION ................................................................................... 16 3.3.1 Problem Statement – Boundary Detection ........................................................................................... 16 3.3.2 Solution Approach – Boundary Detection ........................................................................................... 17 3.4 TASK 3 – FASTENER DETECTION ..................................................................................... 17 3.4.1 Problem Statement – Fastener Detection ............................................................................................ 17 3.4.2 Literature Review – Fastener Detection .............................................................................................. 17 3.4.2.1 Finding Circular Shaped Objects in an Image ................................................................................................. 17 3.4.2.2 Accumulator Array Computation .................................................................................................................... 18 3.4.2.3 Center Estimation ............................................................................................................................................ 18 3.4.2.4 Radius Estimation ..........................................................................................................................................