Maintenance Actions to Address Fatigue Cracking in Steel Bridge Structures: Proposed Guidelines and Commentary

This document provides guidelines for the maintenance actions to address fatigue cracking and details at risk of constraint-induced fracture (CIF) in steel bridges. It is a synthesis of best practices from published literature, project reports, past and ongoing research projects, as well as input from industry professionals gathered through a web-based survey. Intended to be a very practical reference text, it is written with everyone in mind from a maintenance contractor to an asset manager and design engineer, providing detailed descriptions of the driving causes of fatigue cracking and CIF in steel bridges and accepted methods for repair or retrofit. A number of case studies are discussed giving context for the different detail susceptibilities and utilizing a mixture of real-world and rendered images to illustrate the problems and solutions. For each case, a suggested sequence of steps is also provided as a ‘‘how-to.’

Laboratory Testing of Railroad Flatcars for Use as Highway Bridges on Low-Volume Roads to Determine Ultimate Strength and Redundancy

Railroad flatcars (RRFCs) are a convenient option to replace existing deteriorating bridge structures on low-volume roads. They are typically used as the bridge superstructure by placing two or more flatcars side-by-side to achieve the desired bridge width. Utilizing RRFCs as a bridge allows for rapid construction and greater cost savings compared to traditional practices. These benefits make them an attractive solution for rural communities in Indiana, as well as other states. Uncertainty remains about the response under higher loads than could be easily achieved in the field and the level of redundancy of railroad flatcar bridges. Using RRFCs as bridges becomes less economical for counties if they do not display adequate load-path redundancy and are labeled “fracture critical.” If labeled as such, life-cycle costs would rise due to the requirement of an arms-length inspection for each 24 month inspection period. Laboratory testing of a RRFC bridge with two flatcars placed side-by-side allowed for experimental testing under higher loads, as well as increased amounts of instrumentation to better understand the behavior of the RRFCs. As a result of the experimental data, load rating guidelines were developed for RRFC bridges constructed with a fully composite concrete deck. The research also focused on the level of system redundancy in a RRFC bridge after failure of one of the two main box girders. Procedures were developed to estimate whether the remaining longitudinal members provide sufficient available capacity to carry traffic loads

Risk-Based Bridge Inspection Practices

Improving bridge safety, reliability, and the allocation of bridge inspection resources are the goals of the proposed risk-based bridge inspection practices. Currently, most bridges in the United States are inspected at a fixed calendar interval of 24 months, without regard to the condition of the bridge. Newer bridges with little or no damage are inspected with the same frequency as older, more deteriorated bridges thus creating inefficiency in the allocation of inspection resources. The proposed methodology incorporates reliability theory and expert elicitation from the Indiana Department of Transportation’s Risk Assessment Panel, developed during this research, to rationally determine bridge inspection needs. Assessments are made based on the likelihood and consequence of failure for specific bridge components. The likelihood of failure is determined through attributes based on design, loading, and condition characteristics while the consequence of failure is based on expected structural capacity, public safety, and serviceability. By combining the expressions of likelihood and consequence for each component, an optimum inspection interval for the entire bridge can be determined through the use of risk matrices. The methodology was evaluated through case studies involving Indiana bridges. Over 30 years of historical inspection reports were utilized in the back-casting process to evaluate deterioration levels and assess the adequacy of the risk criteria. Results of the case studies conducted during the research indicated that the risk analysis procedures provided suitable inspection intervals ranging from 24 to 72 months for Indiana bridges

Fatigue Life Improvement of Welded Girders with Ultrasonic Impact Treatment

The fatigue life of welded connections can be improved by a variety of post‐weld treatment methods. One of the most effective methods is ultrasonic impact treatment (UIT). This technology may be applied during shop fabrication, but the greatest benefit comes from field retrofitting applications. Tensile cyclic stress ranges drive fatigue crack initiation and growth at the weld toe. This is made worse by tensile residual stresses at the weld toe that can reach the yield strength of the base metal resulting from differential cooling of the weld metal during fabrication. This concentration of tensile residual stress can have the effect of fully tensile cyclic stress ranges even in stress reversal zones of the bridge. UIT induces yield‐strength level compressive residual stresses by cold forming the material at the weld toe. Prior research has demonstrated the effectiveness of 27 kHz UIT systems for improving the fatigue life of welded bridge girders (Fisher and Roy, 2003). The AASHTO LRFD Bridge Construction Specification Commentary C11.9.1 suggests, but does not explicitly require, the use of 27 kHz systems. The existing language can be interpreted as a prohibition on other UIT systems. This report explores the effectiveness of a 20 kHz UIT system applied to transverse stiffener and cover plate termination welds. In this study, fourteen full‐scale girders with welded attachments were subjected to constant amplitude fatigue loading. The test matrix considered variables of stress range and minimum stress. Testing has shown that the 20 kHz UIT system provided equivalent effect to the 27 kHz UIT system. The treatment of the transverse stiffener welds improved the performance from Category C′ to at least Category B. The performance of the cover plate termination welds improved from Category E′ to at least Category C. The results demonstrated 20 kHz UIT as a viable option for enhancing the fatigue performance of welded bridge girders. This finding will expand the alternatives available to bridge owners seeking solutions for extending the life of their aging steel bridge inventory

Monolayer MoS2 strained to 1.3% with a microelectromechanical system

We report on a modified transfer technique for atomically thin materials integrated onto microelectromechanical systems (MEMS) for studying strain physics and creating strain-based devices. Our method tolerates the non-planar structures and fragility of MEMS, while still providing precise positioning and crack free transfer of flakes. Further, our method used the transfer polymer to anchor the 2D crystal to the MEMS, which reduces the fabrication time, increases the yield, and allowed us to exploit the strong mechanical coupling between 2D crystal and polymer to strain the atomically thin system. We successfully strained single atomic layers of molybdenum disulfide (MoS2) with MEMS devices for the first time and achieved greater than 1.3% strain, marking a major milestone for incorporating 2D materials with MEMS We used the established strain response of MoS2 Raman and Photoluminescence spectra to deduce the strain in our crystals and provide a consistency check. We found good comparison between our experiment and literature.Published versio

Member-Level Redundancy of Built-Up Steel Axially Loaded Members

Full-scale fracture tests were completed determining that mechanically-fastened steel built-up axially-loaded tension members are resistant to running fracture when a single component suddenly fractures. This characteristic of built-up member is referred to as Cross-Boundary Fracture Resistance (CBFR). A comprehensive finite element model-based parametric study was also performed investigating the post-fracture load redistribution behavior of multi-component built-up members. Simplified closed-form solutions were developed for engineering analysis of built-up members to evaluate for internal member redundancy and estimate safe inspection intervals that are based on the fatigue life of the member in the assumed faulted condition

Element Level Bridge Inspection: Benefits and Use of Data for Bridge Management

In 2012, Congress passed the Moving Ahead for Progress in the 21st Century Act (MAP-21) and committed to the development of a data-driven, risk based approach to asset management in the United States. This law requires the collection and submission of element level bridge inspection data for all National Highway System bridges, in addition to the National Bridge Inspection condition rating data. Ultimately, the data collected during element level bridge inspections should satisfy the requirements of the Federal Highway Administration and MAP-21 and be utilized by INDOT to evaluate bridge condition, predict deterioration, and guide decision making. The objective of this project is to develop recommendations for element level bridge inspection techniques, data collection, and inspector training based on a survey of INDOT peer agencies and a literature review of existing research and bridge inspection guidance. In order to collect consistent and reliable data, a rigorous inspector training program and detailed quality control procedures are necessary. INDOT must provide inspectors with the tools to be successful, including clearly defined expectations and instructions, comprehensive training and technical support, and effective inspection equipment. Similarly, robust quality control measures and periodic performance testing should be implemented to improve inspection quality and assess the agency’s performance

Band Gap Engineering with Ultralarge Biaxial Strains in Suspended Monolayer MoS2

We demonstrate the continuous and reversible tuning of the optical band gap of suspended monolayer MoS2 membranes by as much as 500 meV by applying very large biaxial strains. By using chemical vapor deposition (CVD) to grow crystals that are highly impermeable to gas, we are able to apply a pressure difference across suspended membranes to induce biaxial strains. We observe the effect of strain on the energy and intensity of the peaks in the photoluminescence (PL) spectrum, and find a linear tuning rate of the optical band gap of 99 meV/%. This method is then used to study the PL spectra of bilayer and trilayer devices under strain, and to find the shift rates and Gr\"uneisen parameters of two Raman modes in monolayer MoS2. Finally, we use this result to show that we can apply biaxial strains as large as 5.6% across micron sized areas, and report evidence for the strain tuning of higher level optical transitions.Comment: Nano Lett., Article ASA

Mutual information in random Boolean models of regulatory networks

The amount of mutual information contained in time series of two elements gives a measure of how well their activities are coordinated. In a large, complex network of interacting elements, such as a genetic regulatory network within a cell, the average of the mutual information over all pairs is a global measure of how well the system can coordinate its internal dynamics. We study this average pairwise mutual information in random Boolean networks (RBNs) as a function of the distribution of Boolean rules implemented at each element, assuming that the links in the network are randomly placed. Efficient numerical methods for calculating show that as the number of network nodes N approaches infinity, the quantity N exhibits a discontinuity at parameter values corresponding to critical RBNs. For finite systems it peaks near the critical value, but slightly in the disordered regime for typical parameter variations. The source of high values of N is the indirect correlations between pairs of elements from different long chains with a common starting point. The contribution from pairs that are directly linked approaches zero for critical networks and peaks deep in the disordered regime.Comment: 11 pages, 6 figures; Minor revisions for clarity and figure format, one reference adde