fatigue and fracture assessment · fatigue and fracture assessment jesse stuart highway bridge...
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FATIGUE AND FRACTUREFATIGUE AND FRACTUREASSESSMENTASSESSMENT
JESSE STUARTJESSE STUARTHIGHWAY BRIDGEHIGHWAY BRIDGE
HUNTINGTON DISTRICTHUNTINGTON DISTRICT
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John J. Jaeger, Ph.D., P.E.John J. Jaeger, Ph.D., P.E.(o) 304(o) 304--399399--52545254(c) 304(c) 304--444444--60436043
US Army Corps of EngineersUS Army Corps of [email protected]@Lrh01.usace.army.mil
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View of Jesse Stuart Highway Bridge looking northView of Jesse Stuart Highway Bridge looking north(downstream) from Kentucky side of the Ohio River.(downstream) from Kentucky side of the Ohio River.
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Longitudinal stiffener termination, Girder A’, Span 11, Unit 3Longitudinal stiffener termination, Girder A’, Span 11, Unit 3
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Crack at the Termination of the Longitudinal Web StiffenersCrack at the Termination of the Longitudinal Web Stiffeners
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CloseClose--up view of cracked longitudinal stiffener termination.up view of cracked longitudinal stiffener termination.
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Web gap cracking at inside (upstream) web faceWeb gap cracking at inside (upstream) web faceat Cross Frame 1, Span 4 of Girder A, Unit 2.at Cross Frame 1, Span 4 of Girder A, Unit 2.
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Web gap cracking at outside (downstream) web face atWeb gap cracking at outside (downstream) web face atCross Frame 2, Span 4 of Girder A, Unit 2.Cross Frame 2, Span 4 of Girder A, Unit 2.
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Web gap cracking at inside (upstream) face atWeb gap cracking at inside (upstream) face atCross Frame 2, Span 4 of Girder A, Unit 2.Cross Frame 2, Span 4 of Girder A, Unit 2.
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Web gap cracking at inside (upstream) face atWeb gap cracking at inside (upstream) face atCross Frame 2, Span 4 of Girder A, Unit 2.Cross Frame 2, Span 4 of Girder A, Unit 2.
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Web gap cracking at inside (upstream) face atWeb gap cracking at inside (upstream) face atCross Frame 3, Span 4 of Girder A, Unit 2Cross Frame 3, Span 4 of Girder A, Unit 2
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Web gap cracking at inside (upstream) face atWeb gap cracking at inside (upstream) face atCross Frame 3, Span 4 of Girder A, Unit 2.Cross Frame 3, Span 4 of Girder A, Unit 2.
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Web gap cracking at outside (downstream) web face atWeb gap cracking at outside (downstream) web face atCross Frame 3, Span 4 of Girder A, Unit 2.Cross Frame 3, Span 4 of Girder A, Unit 2.
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General Types of Fatigue CrackingGeneral Types of Fatigue Cracking
LoadLoad--InducedInducedDistortionDistortion--InducedInduced
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LoadLoad--Induced Fatigue CrackingInduced Fatigue Cracking
Nominal Stress RangeNominal Stress RangeNumber of Applied Load CyclesNumber of Applied Load CyclesConnection DetailsConnection Details
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LoadLoad--Induced FatigueInduced Fatigue(Type 3 Cracking)(Type 3 Cracking)
Longitudinal Stiffener TerminationLongitudinal Stiffener Termination–– Category E DetailCategory E Detail–– Stress Range 6.3Stress Range 6.3 ksiksi < 13.0< 13.0 ksiksi–– Termination Opposite a Transverse StiffenerTermination Opposite a Transverse Stiffener
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DistortionDistortion--induced Fatigue Crackinginduced Fatigue Cracking(Type 1 & 2 Cracking)(Type 1 & 2 Cracking)
Stress Ranges ComplexStress Ranges ComplexLocalized Stresses unintended/UnknownLocalized Stresses unintended/UnknownOutOut--ofof--Plane DistortionPlane Distortion
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View of typical cross frame in Unit 2.View of typical cross frame in Unit 2.
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DistortionDistortion--Induced FatigueInduced Fatigue
Transverse Stiffener ConnectionTransverse Stiffener Connection–– “Tight Fit (No Weld)”“Tight Fit (No Weld)”
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Typical Cracks in Center Spans*Note measurements from Periodic Inspections. Blue writing is from FY01. Black writingis from FY03. Top crack grew 5/8” and the lower crack grew 1/8” in a two year period.
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View of typical cross frame in Unit 1 (and Unit 3).View of typical cross frame in Unit 1 (and Unit 3).
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FractureFracture AssessmentAssessmentThree Charpy V-Notch impact test specimens were testedfrom each of Units 2 and 3.Unit 2 web specimens averaged energy absorption is 261 ft-lbf.Unit 3 web specimens averaged energy absorption is 38 ft-lbf(low value 29 ft-lbf)Test temperature 40F corresponding to AASHTOTemperature Zone 2AASHTO required minimum energy absorbed value is 25 ft-lbf for ASTM 588 in Temperature Zone II.LEFM used to assess Type 3 crack as “thru-thickness ininfinite wide plate”.Critical crack length is conservatively twice the existing lengthof 2.25”.
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Retrofit for Type 1 and Type 2 Cracks.Retrofit for Type 1 and Type 2 Cracks.
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Retrofit for Type 3 CrackRetrofit for Type 3 Crack
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SummarySummary
42 fatigue cracks exist as of September 200342 fatigue cracks exist as of September 2003Probable cause is loadProbable cause is load--induced and distortioninduced and distortion--induced fatigue crackinginduced fatigue crackingLimited material testing indicates adequateLimited material testing indicates adequatefracture toughness for websfracture toughness for websObserved Type 1, 2, & 3 cracking does notObserved Type 1, 2, & 3 cracking does notimpose an immediate structural threat.impose an immediate structural threat.Existing web gap cracking does not reduce loadExisting web gap cracking does not reduce load--carrying capacity of girders.carrying capacity of girders.Permitted loads will be assessed and limitedPermitted loads will be assessed and limitedwhere possible.where possible.
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Discussion!Discussion!
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