Bridges for Service Life Beyond 100 Years: Innovative Systems, Subsystems and Components

SHRP 2 | Project R19A

SHRP 2- Project (R19A)

Bridges for Service Life beyond 100 Years: Innovative Systems, Subsystems, and Components

Principal Investigator: Dr. Atorod Azizinamini, P.E. Professor and Chairperson Florida International University Miami, Florida Program Officer: Dr. Monica Starnes (2007-2010) Mark Bush, P.E., PTOE (Jan 2011- Dec 2011)

Jerry DiMaggio (Jan 2012 to present)

Main Product
Design Guide for Bridges for Service Life,
hereafter referred to as the

Guide.
Provides systematic and general approach for design for service life is developed.
Camera ready copy of the Guide was submitted Feb 2013 Should be available by end of March 2013

Research Team Members

Florida International University University of Nebraska HDR Six (6) Ph.D., students Attkins Three (3) M.S. students Celik Ozyildirim Three (2) Research Associates KTA Vector Corrosion University of Delaware Georgia Inst. Of Tech

AASHTO T-9
Ralph Oesterle, CTL Jointless Bridges Lloryd Sterling Water Proofing Bridge Deck Martin Burke Consultant Jointless Bridges Charles Roeder- University of Washington- Bearings

Concrete Durability Substructures Expansion Joints, Joints and Jointless Structural Steel Protection Concrete Bridges

Bridge Decks Bearings Fatigue and Fracture

Survey of DOTs Input of Individuals Outside the Team Analysis of NBI Data

Input of AASHTO Sub-committees Input from Industry

Steel Bridges

Start

Major Categories

Problematic Issues

Design Guide for Bridges for Service Life

Chapter 2 Chapter 7 Chapter 12 Chapter 3 Chapter 8 Chapter 13 Chapter 4 Chapter 5 Chapter 9 Chapter 10 Chapter 14 Chapter 15

Chapter 1

Chapter 6

Chapter 11

AASHTO Specifications

Stand Alone Guide

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Strategy, Technology and Ranking Tables

Suggested Topics

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Project main product Design Guide for Bridges for Service Life

Guide is primarily for bridges with spans of less than 300 ft.

However, Guide provides a frame work that could be used to address service life design of any span bridges

Review of bridges that have lasted more than 100 years indicates:

1-

Maintainable and well maintained over their 100year lives due to extreme importance or high capital replacement cost,
2- Originally over-designed

Traditional Approaches
- Service life of bridges in various codes and an - Direct or indirect and isolated form, specifying the use of certain details or properties such as cover thickness, maximum crack width, concrete compressive strength, etc.

How to accomplish design for service life

- At the design stage - Systematic and comprehensive - Plan should eliminate the surprise factor for the owner

OBJECTIVES OF THE GUIDE

The main objective of the Guide is to provide information about, and define procedures for systematically designing for service life and durability for both new and existing bridges.

GUIDE Approach
- Provide body of knowledge to make decision - Establish array of solutions - Allow incorporating local experiences, practice and preferences - Let designer and owner select the optimum solution

Chapters Design Guide for

Bridges for Service Life

General categories of information included in each Chapter

1234Introduction Factors Affecting Service Life Options for Enhancing Service Life Strategy for developing solution for specific problem 5- Management Plan 6- Examples

Sources of Information Being Used to Develop the Guide

Available information in AASHTO specifications Synthesis of state of the knowledge

Results of R19A research (about 40%)

Guide for Bridges for Life

Industry inputs
Others, such as fib C5 Commission

Input from other experts

AASHTO and DOT inputs

Chapter 1- Design for Service Life: general Framework Chapter 1-This chapter provides an overview of the
approach used in the Guide for design for service life. Chapter 1, also describes terminologies used throughout the guide and various relationships that exist between service life of bridge element, component, subsystem and system and bridge design life as used in AASHTO Specifications. It provides an introduction to the different philosophies used to predict service life. It is essential to read this chapter before proceeding with use of the Guide.

Chapter 2- Bridge System Selection Chapter 2-This Chapter provides a description of various
bridge systems and factors that affect their service life. Chapter includes the description of a general strategy and rational procedure for selecting the optimum bridge system, subsystems, components and elements, considering specific project limitations and requirements, such as climate, traffic, usage and importance. The discussion includes both existing and new bridges, with more detail provided in other chapters

Chapter 3- Materials Chapter 3-This chapter provides general properties and

durability characteristics of the two most commonly used materials in bridge systems, namely steel and concrete. For each material, a general description of variables affecting the service life is provided, followed by strategies used to mitigate them. This chapter forms the basis for materials used in bridge elements, components and subsystems specifically addressed in other chapters of the Guide.

Chapter 4- Bridge Deck Chapter 4-This chapter provides descriptions of various

bridge deck types and essential information related to their service life, such as modes of deterioration and strategies to mitigate them. The chapter concentrates on cast-in-place and precast concrete bridge decks.

Chapter 4- Bridge Deck New Concepts- Self stressing Waterproofing Manual

Chapter 5- Corrosion Protection of Concrete Bridges Chapter 5-This chapter provides basic mechanisms
causing corrosion of reinforcement embedded in concrete and strategies for preventing corrosion of reinforcement in concrete bridges
Fe Fe2+ + 2e Fe2+ + 2ClFeCl2 Chloride Contaminated Concrete

FeCl2 + 2OH-

Fe(OH)2 + 2ClFe2O3 + 2H2O 2Fe(OH)2 + 1/2O2

2OH1/ O 2 2

2e -

+ H2O + 2e - 2OH-

Chapter 6- Corrosion Protection of Steel Bridges Chapter 6-This chapter provides descriptions of various
coating systems using paint, galvanizing and metalizing, and descriptions of corrosion resistant steels along with factors affecting their service life. Various options for preventing corrosion of steel bridges and general approaches that could lead to bridge coatings with enhanced service life are presented.

Chapter 7- Fatigue and Fracture Chapter 7-This chapter provides the basics of fatigue
and fracture and factors that cause fatigue and fracture in steel bridges. Various available options to repair observed cracking in steel bridges are also presented

Chapter 8- Jointless Bridges Chapter 8- This chapter provides descriptions,

advantages and disadvantages of various jointless bridge systems, and provides complete steps for design of jointless integral abutment bridges. This chapter provides design procedures to extend the application of jointless integral bridges to curved girder bridges. This chapter also introduces new details and integral abutment systems, where expansion joints are completely eliminated, even at the end of approach slabs.

Chapter 8- Jointless Bridges Provides A to Z design of jointless bridges Provides new details- Pin Head Provisions to apply to curved girder bridges Introduces seamless bridge system

HP12x84-Medium Clay
10 9
Pinned-Strong

Disp. Capacity (in)

8 7 6 5 4 3 2 1 0
0 50

Pinned-Weak Fixed-Strong Fixed-Weak

100

150

200

Axial Load (kips)

Transition Zone Bridge Approach

Abutment

Small Piles Secondary Slab

JPCP

Chapter 9- Bridge Expansion Devices Chapter 9- The Guide encourages, eliminating the use of
expansion joints, however, expansion joints may be needed when the total bridge length exceeds practical limits of jointless bridges. This chapter provides description of various expansion joints used in practice, observed modes of failure for each and potential strategies to mitigate them.

Chapter 10- Bridge Bearings Chapter 10-This chapter provides descriptions of

various bearing types, and lists factors that affect their service life with strategies to mitigate them. New materials capable of providing long service life for sliding surfaces are introduced as well as deterioration models for sliding surfaces. The Guide emphasizes use of elastomeric bearing pads for long service life.

100 90

Thickness (Percent of initial thickness)

80 70 60 50 40 30 20 10 0 0.00

PTFE Sample #1 PTFE Sample #2 MSM Sample #1 MSM Sample #2 Fluorogold Sample #1 Fluorogold Sample #2

5.00

10.00

15.00

20.00

25.00

Travel Distance (Miles)

 = (, , )
() 365 = 2 1 1.33 () 63360

Eq. 1
Eq. 1

() = () 365/5280
() = 1 () 5280 Eq. 4

Eq. 3

(TD) Demand = () + () + ()
100 90

Thickness (Percent of initial thickness)

80 70 60 50 40 30 20 10 0 0.00

PTFE Sample #1 PTFE Sample #2 MSM Sample #1 MSM Sample #2 Fluorogold Sample #1 Fluorogold Sample #2

5.00

10.00

15.00

20.00

25.00

Travel Distance (Miles)

Chapter 11- Life Cycle Cost Analysis Chapter 11-This chapter provides essential information
for incorporating Life Cycle Cost Analysis (LCCA) in bridge system, subsystem, component and element selection. This chapter concentrates on general features and elements of incorporating LCCA in the design process, emphasizing consideration of project costs throughout its service life.
Uncertainty in Timing Uncertainty in Construction Cost
Probability Distribution of NPV

Uncertainty in Repair Costs

Steps in Design for Service Life

Step 1- Identify the factors that influence the service life of

bridge elements, components and subsystems, such as traffic, environmental or internal defects and risk to damage.

Step 2- Identify the deterioration and damage mechanism,

such as freeze/thaw cycles

Step 3- Identify modes of failures and consequences. For

instance, the corrosion of reinforcement, causing corrosion induced cracking and loss of strength.

Steps in Design for Service Life

Step 4- Identify suitable approaches for mitigating the failure modes or

assessing risk of damage, through life cycle cost analysis. For instance, use of higher performing materials for sliding surfaces in bearings or use of material prone to deterioration at lower initial cost.

Step 5- Estimate service life of the bridge element, component or

subsystem using Finite or Target Service Life Design approaches.

Step 6- Compare the service life of the bridge element, component or

subsystem to the service life of the bridge system and develop appropriate maintenance, retrofit and/or replacement plan.

Step 7- Develop design, fabrication, construction, operation, maintenance,

replacement and management plans for achieving the specified design life for the bridge system.

Footnote Step 5
What is needed to Estimate the Service Life of Bridge Elements, Components and Subsystems
Deterioration Models Examples

x C ( x , t ) Co 1 erf 2 Dct
Fatigue Design Approach in AASHTO LRFD

Flow Charts to Use Guide

Series of flow charts are provided, within each chapter, that allows an engineer with minimal design experience to navigate through design for service life steps. Next slide shows the main steps, without elaborating on the details

Fault Tree- Identifying factors affecting service life

The fault tree is used to systematically identify the factors that can affect service life of a particular bridge element, component, or subsystem.

Reduced Service Life of Cast-in-Place Bridge Deck

Caused by Obsolescence

Caused by Deficiency

Load-Induced

Natural or Man-Made Hazards

Production/ Operation Defects

Load-Induced

Traffic-Induced Loads

SystemDependent Loads

Fatigue

Overload

Wear

Differential Shrinkage

Thermal

System Framing Restraint

Example- Bridge Deck

Bridge Deck System Component Selection Process

1.a: Identify Local Operational and Site Requirements

1.b: Identify Local Factors Affecting Service Life

2: Identify Feasible Deck Alternatives Satisfying Design Provisions of AASHTO LRFD, Operational, Site and Bridge System Requirements

3: For Each Alternative, Identify Factors Affecting Service Life Following Fault Tree

Go To A

8.a: Go To Next Alternative

5: Deck SL System TDSL? Yes

No

5.a: Identify Rehab or Replacement Requirements

6: Identify Maintenance Requirements 7: Develop Life Cycle Costs

Yes

8: Addl. Deck Alternative? No

9: Compare Alternatives and Select Deck System

1A: Identify Individual Factor Affecting Service Life Considering Each Branch of Fault Tree 2A.a: Identify Consequence and Determine Appropriate Strategies for Avoidance or Mitigation

3A.a: Go to Next Factor

2A: Does Factor Apply? No No

Yes

3A: All Factors Considered?

Yes

2A.b: Modify Bridge Deck Configuration

4A: Modified Bridge Deck Configuration for Deck Alternative under Consideration

Go To B

Operational Category
Traffic capacity requirements Traffic volumes and required capacity Truck volumes Special vehicle uses

Operational Criteria to Be Specified

Urban arterial, 4 lanes, 40 mph 24000 ADT NB and SB 10% Overload possible

The local environment or man-made hazard category

Maintain 2 existing lanes

Mixed use requirements

Traffic, pedestrians, bicycle lane

Vehicle loads and special vehicle load requirements

HL 93 with typical legal and permit loads No special construction loads Overload with 20 kip tire loads (HL93 truck configuration) Studded tires used in winter

Bridge Deck Systems

Advantage Readily available material. Accommodates tolerances. Low-cost. Readily available material. Typically prestressed, reducing cracking. Lightweight system. Prefabricated system.

Disadvantage

Cast-In-Place Concrete Deck Systems

Susceptible to cracking and corrosion.

Precast Concrete Deck Systems

Requires construction joints between components. Higher initial cost. Requires protective coatings. Difficult tolerance adjustments. High cost. Limited span range. Susceptible to wear without overlays. Susceptible to moisture degradation. High cost. Limited history. Requires overlay for traction.

Metal Deck Systems

Timber Deck Systems

Lightweight system. Constructible with unskilled labor. Low-cost. Lightweight system. Noncorrosive system.

FRP Deck Systems

Service Life Issue Overload

Corresponding Job Requirements HL93 with 20 kip wheel load, applied once a month

Section 5.3.2.1.1.2

Mitigating Strategy Increase deck thickness Minimize bar spacing for given amount of steel

Advantage Minimizes cracking Improves crack control Minimizes possibility of reinforcement failure Identified in Chapter 3 Protects surface from direct contact with tires Identifies design criteria for establishing stresses

Disadvantage Adds weight to bridge structure, increases cost More labor to install and higher cost May increase area of steel Identified in Chapter 3 Requires periodic rehabilitation every 10 to 20 years Restraining force may cause cracking in deck. Refer to Chapter 8.

Fatigue Wear and Abrasion

24000 ADT NB and SB 5.3.2.1.1.1 and 10% truck volume Studded tires on high 5.3.2.1.1.3 level of service bridge

Design per LRFD Specifications Implement concrete mix design strategies Implement membranes and overlays Develop accurate system model Use low modulus concrete mix design for composite decks Use high creep concrete mix designed for composite decks Develop composite action after concrete has hardened

System Framing Restraint Differential Shrinkage

Deck shrinkage restraint from shear studs

5.3.2.1.2.3

Use precast deck panels Reactive Ingredients ASR/ACR Coastal Climate Humidity Thermal Climate Freeze/Thaw Local aggregates are reactive RH average 70% Multiple cycles of freeze/thaw expected

Allows additional strain to be Typically lower in strength and may accommodated up to cracking stress be subject to wear and abrasion Uncommon mix design. Difficult to Reduces lockedin stresses assess stress relief Little experience with experimental Allows slippage between deck and systems. Friction reduction difficult supporting members, minimizing to assess. Introduces numerous locked-in stresses construction joints. Grout integrity issues in closed void systems. Allows slippage between deck and Introduces numerous construction supporting members, minimizing joints locked-in stresses Refer to Chapter 3

5.3.2.2.4.1

Use materials and mix designs that Refer to Chapter 3 are not sensitive to aggregate Use materials that are not sensitive Refer to Chapter 3 to moisture content Refer to Chapter 3 for strategies relating to freeze/thaw Refer to Chapter 3 for strategies relating to freeze/thaw

5.3.2.2.2.2

Refer to Chapter 3 Refer to Chapter 3 for strategies relating to freeze/thaw

5.3.2.2.1.2

Overload

Fatigue

Wear

System Restraint

Differential Shrinkage

Deicing

Freeze/ Thaw

Salt spray

Humidity

ASR/ACR

Increase Deck Thinness

Design per AASHTO

Concrete mix

Accurate modeling Concrete mix during Use mix with analysis of low modulus the system

Impermeable Concrete

Concrete mix air content

Stainless steel

Use aggregate that are not sensitive to humidity

Concrete mix nonreactive aggregate

Membrane and overlay

Stainless Steel

Stay in place metal deck to protect bottom Deck bottom sealer and top membrane

Increase thickness

Specify nonchloride based deicing Membrane and Overlay

Before

Design

for Service Life

Alt. 1 Good Mix

Alt. 2 Stainless steel

Alt. 3 Large cover

Alt. 4 Membrane

Alternative AASHTO Base Design 1 2 3 4

Main Feature to address corrosion N/A Impermeable concrete using silica fume Use of 316-stainless steel Increasing concrete cover Using membrane and overlay

Initial cost $37,215 $44,645 $152,753 $46,519 $109,541

Life cycle cost $774,676 $277,550 $152,753 $691,114 $172,252

Camera ready copy of the Guide was submitted Feb 2013 Should be available by end of March 2013 Atorod Azizinamini aazizina@fiu.edu 402-770-6210