Management of Long-span

Bridges

October, 2013
Bridge Maintenance Section
Naruto Operation Center, HSBE

Contents
Maintenance of Ohnaruto Bridge
Steel structures
Concrete structures
Maintenance of concrete structures
Measure for salt attack on Tozaki Viaduct
Seismic retrofitting of Magozaki Viaduct
Seismic retrofitting of Kameura Viaduct
Measure for salt attack on Kameura Viaduct
Suggestions for site works
1

Ohnaruto Bridge

Tozaki Viaduct

Magozaki Viaduct

Kameura Viaduct

Ohnaruto Bridge
Management of steel structures

Corrosion prevention Recoating is planned.

Completed in 1985,
Recoating of girder (1998~2005), main tower (2004~2006).
To ensure long-life of painting, spot repainting is prepared at present.
(connection parts and bearing parts are easily corroded. remark points)
6

Local corrosion

Repair for the ends of suspenders (1)

Suspender:
Rope between cable and girder

Cable

Suspender

Girder

Corrosion of suspender (1)

End of suspender

2
9

Corrosion of suspender (2)

Section of Rope
10
2

Repair technique of suspender

1.
scaffolding

Scaffolding

2.
Loosening

3.
Inspection

Section inspection

4.
Removal

Removal of paint

5.
Filling

Filling paste

6.
Repair

7.
Tension
installing

Repair of surface

Completion

11

Corrosion protection of multi-pile foundation

12

Corrosion protection (1)

T.P +7.00

Splash zone
Epoxy polymer paint for
underwater type

T.P +4.50
T.P +4.00

T.P +1.10

Tidal zone
Cover with petrolatum & titan

H.W.L T.P +0.8m

T.P -0.40

M.S.L T.P +0.1m

L.W.L T.P -0.4m

Underwater
Electrical prevention

4,600

13

Corrosion protection (2)

ionization tendency

Small

Large

Before repair
Electric wire

After repair

Pile
(Fe)

Anode
Al

Splash zone

Tidal zone
14

Corrosion protection (3)

Tidal zone: installing titan plate
Stad bolts

Titan cover

Titan cover

Underwater welding

15

Concrete lining for tower foundation (1)

Damage of lining

Peeling

Peeling

Peeling

16

Required performance of lining

Performance

Blocking
Adhesiveness

Flexibility
Durability

Spec.
Intrusion of chloric ion
< 110-3 mg/cm2/day
Adhesive strength with concrete
> 0.7 N/mm2
No damage of painting, until crack width <
2.0
Damage is minimal in existing repaired
bridges.

17

Removal of existing lining

Exposure of concrete surface or
existing epoxy-coated pate

execution

execution

Measure for scatter

Sheet is set by using rail on the top of foundation.
Blast machine with dust catcher is used.
18

Repair of crack
Crack more than 0.2mm is repaired.

Cutting

Filling

Work and material

Cutting (width 15 & depth 15) is made and sealing material is filled.
Sealing material is made from silicon.
19

Section repair
Locations of rust stain, concrete floated or peeled

Removal of concrete and rebar

Surface repair

Adhesive material

Work and material

Removal of concrete and rebar corroded measure of corrosion protection
on steel members cast repair material
Thickness of repair material > 30 mm removal of concrete behind the steel
Members to ensure bonding with existing concrete
Thickness of repair material = 10 mm adhesive material is used to bond with
concrete
20

Flexible paint & Polybutadiene

Recoating

Recoating

21

Polyurethane (rapid hardening)

Constitution
Fluorine resin paint
Polyurethane

Construction

machine

Second primer
Silica
First primer

Work flow

Sprayflat

Spray(slope)

Paint with first primer

Scatter of silica to enhance adhesiveness
Paint with second primer
Blow of polyurethane
Application of fluorine resin paint
22

Quality Control
Temperature of concrete surface
Purpose: to keep performance of lining material
Method: thermometer
Spec.: surface temperature < 40

Water content of concrete surface

Purpose: to keep adhesive performance of primer
Method: water measurement with high-wave length
Spec.: surface water content < 8.0 %

Amount of salt deposited

Purpose: to keep durability of lining
Method: measurement of salt deposition
Spec.: < 100 mg/m2

23

Measurement of salt

Gauze wipe the surface of the concrete

Rinse the salt adhering to the gauze

50cm50c
m
Sample solution

Detecting
tube

150ml

24

Quality control

adhesiveness

Flexible paint

Method: JIS A 6909 - 7.9.2a

Tensile force / loaded area (16002(4040))
Spec.: > 1N/mm2
Test results
Sort
Polybutadiene

Flexible

Location

Observe
d(kN)

Ad.
(/2)

plane

3.92

2.45

slope

5.40

3.38

plane

3.88

2.43

Paint is peeled

slope

5.68

3.55

No peeling

plane

4.70

2.94

Paint is peeled

slope

3.42

2.14

Paint is peeled.

Paint

Peeling
No peeling: 95
Peeling: 5
No peeling: 55
Peeling: 45

Polybutadiene

P o l y u r e t h a n e
Polyurethane

25

Quality control
Thickness of flexible and polybutadiene
Method: wet thickness is measured with gauge. dry
thickness is measured with electro-magnetic gauge.
Spec.: more than required dry thickness
more than 70% of required dry thickness
electro-magnetic gauge

Thickness of polyurethane
method: time of blow work
measurement of dry thickness
Spec.: > 45 sec/
more than 70% of required dry thickness
test execution

measurement of dry thickness

How to calculate blow time

Blow volume of 1 = dry thickness unit weight

= 2500m 1100kg/
= 2.75kg/ 3.0kg/
Blow volume / hour = 4.0kg/min
Blow time of 1 = 3.0kg/4.0kg/min60sec
= 45sec/
26

Management of concrete structures

Tozaki Viaduct

Side view

Kobe

1A

3P: finish 4P: finish

5P: finish

Naruto

6P: finish

7P: finish

8A

27

Before working (T)

Spalling off

Upper part of pier

Whole view from T6P

Base of pier
28

After working ()
Upper part of pier

Whole view from T6P

Base of pier
29

Survey
condition

scaffolding

survey

hammering
Non-destructive test
(chlorine, carbonation)
Cost of scaffolding is very large
because the structure is so huge.
As simple test, hammering test is
done with rope access.
Survey by rope access

30

Condition of concrete pier

Rust is found on main rebar

but it is almost sound.

Flake of joint part

Rust is found on
hoop tie and it is
damaged.

After chipping

Exposure of rebars
31

Survey result (4)

Crack prevention rebar
Hoop tie

Cover (compared with design)

crack prevention rebar: 69.0m (+22.0mm)
hoop tie: 101.6mm (3.9mm)
main rebar: 129.4mm (4.9mm)

Main rebar

D6

Condition
crack prevention rebar: rust is found.
Some are broken.
hoop tie: rust is found but almost still
sound.
main rebar: rust is found but almost
still sound.

100
47 D19 D51
unit: mm
124.5
Arrangement(design)
32

Future prediction

amount of chloride ions

3
kg/

Chlorine density front of main rebar is more than

1.2kg/m3 before five years.
In 50 years, more than 2.5kg/m3 at the front of main
rebar and 1.2kg/m3 at the back of main rebar.
10
9
prerequisite condition
8

surface chlorine density

: 8.04kg/m3
spread coefficient
: 0.89cm/year
initial chlorine density
: 0.4kg/m3

6
5
4
3

2.5kg/m3

1.2kg/m3

1
0
0

19
50

10

12

depth
(cm)
5
100

14

16

18

20

0
19

:Survey(2007:estimation)
:after 5 years
:after 10 years
:after 50 years
:after 100 years :Study (2007:Measurement)

33

Future prediction after repair

After repair, chlorine density is less than 1.2kg/m3
(limit of corrosion) even at the hoop tie position.
Chipping concrete
(t=9cm)
9cm

amount of chloride ions

kg/ 3)
(kg/m

10
9
8
7

Crack prevention rebar

) (removal)

6
5

4
3

2.5kg/m

1.2kg/m3

1
0
0

10

12

14

16

18

20

cm)
depth
(cm)
19

10

50

100

:Survey(2007:estimation)
:after 5 years
:after 10 years
:after 50 years
:after 100 years

Prediction of chloride ion prediction

34

Chipping concrete
Chipping concrete

Removal of rust
35

Repair of pier section

Execution work

36

Lining concrete surface

Execution
Spec. of lining
Lower
Epoxy
resin
primer

Interval

Middle

Interval

3h

7d

Polyurethane
resin
(2500)

30m

3d

Top
Flexible
fluorine
paint
(30)

Repair of pin hole

37

Seismic Retrofitting of Magozaki Viaduct

Carbon fiber jacking method

Carbon fiber
+ RC jacking method

0
.75

134050()

Bridge
length 133.7m
133700
44.3m
44300

44.3m
44300

5A

M1P

M3A

3000

28560

3000

RL

400

M2P

3000

800

200

44.3m
44300

18810

150
400

82.

1+
TA.

20035

48
.0+
STA

RL

45000

12500
12500
5
1.
1:

38

11380

11380

4000
M3P

6269

3000

3400

3000

15000

9091

15000

1650

3000

9563

9170

3000

5050

3642

3700

3918

M2P
3886

M1P

2780

2795

Retrofitting of pier and concrete lining

M1P

21000

RC jacking
method

5A

M2P

21000

Legend
Carbon fiber (3 layers)

Carbon fiber (6 layers)

Carbon fiber (4 layers)

Carbon fiber (9 layers)

Carbon fiber (5 layers)

Concrete lining

39

Carbon fiber lining

Specification of carbon fiber work

treatment
Surface
(0.4/)
Primer(adhesive layer)
Epoxy
pate(flatness control)
(0.3/)
Adhesive(lower
coat)
(0.5/)
Carbon
fiber
sheet
3~9 layers
FTS-C1-3039
Adhesive(overcoat)
(0.3/)
Finishing
material
1mm
Epoxy
resin coat(middle layer)
0.14/
0.12/
Fluorine
resin coat(surface layer)

40

Retrofitting of Kameura Viaduct

Pier strengthening

Installing damper

Displacement restriction device

Bump prevention device

Girder strengthening

41

Pier strengthening

RC jacking method

42

Damper (displacement restriction)

43

Displacement restriction device (longitudinally)

44

Bump prevention device

45

Girder strengthening(1)

Strengthening by carbon fiber

46

Girder strengthening(2)
Side view

50m

Carbon fiber

Plane figure
16.5
9.5

hinge

50m

Carbon fiber
16.5
9.5
6.0

(unit:m)

0.5

Carbon fiber
47