Lightweight Bridge Decks Conference

CONFERENCE PROGRAMME

Lightweight Bridge Decks
March 27th and March 28th, 2003
Maritime Simulation – Rotterdam, the Netherlands

CONFERENCE PROGRAMME

THURSDAY 27th March, 2003

09.00 Registration & Coffee served in Sponsor display area
09.30 Opening Conference, Conference Chairman: Mr. Peter Head - Faber Maunsell, UK.

09.35 - Key Note Speech "Gibraltar Strait Bridge and the advancement of bridge technologies"
Mr. Chuck Seim - Vice President, Prof. T.Y. Lin International, USA

In the beginning there was only fallen trees and stone slabs for making bridges. Spans were short and so was their durability. Bridge builders then piled stones together in the form of arches for longer spans. This form endured for 2,000 years until Abraham Darby III built the first cast iron bridge in the form of an arch in 1779 at Coalbrookdale, England. Thomas Telford improved on the cast iron arch form and then built the first long span wrought iron suspension bridge, a then new bridge form, across the Strait of Menai in England in 1826. The suspension bridge grew in length as materials improved and structural analysis advanced. Today the suspension bridge is King of all bridge types with the newest and the longest, 1998 and nearly 2,000 meters, located in Japan. There is little wonder why Prof. T. Y. Lin used this form and stretched it to 5,000 meters for bridging the Strait of Gibraltar. Prof. Lin’s long-span design proved to be lower in cost than a shorter-span alternative proposal.
The story of bridges and bridge technologies is fascinating and today we are poised at the beginning of a new advancement. Lightweight composite materials that are as strong as steel and as light as dirt promises to advance the art and practice of bridge engineering a giant step. Bridge designers need to apply this new material in forms that complements its potential, and not copy old forms as did Abraham Darby with arches. The time has come for using lightweight composites in bridge engineering.

Session A Design Criteria and Design Rules

10.05 - "Traffic loads on bridges and actual traffic loads in the Netherlands"
Mr. Sipke E. van Manen - Ministry of Transport, Public Works and Water Management, The Netherlands

This paper describes the research that has been performed to ensure that the design loads, as specified in the Eurocode 1, part 3, Traffic loads on bridges, will provide bridges and bridge decks that are sufficiently safe with respect to the conditions and standards in the Netherlands. Traffic loads and traffic intensities have been measured on different locations in the Netherlands and these measurements have statistically been interpreted and extrapolated to future use. Existing design loads are compared to proposed design loads. The measured load configuration on the whole bridge was statistically interpreted and compared to the distributed design loads. Finally the fatigue design procedure and the fatigue load assumptions were checked with the measurements.

10.25 - "Developments and design guidelines for fibre-reinforced polymer bridge decks"
Mr. B. Sadka HA, Dr. A Daly TRL. - UK Highways Agency, UK

The UK Highways Agency commissioned a research programme to investigate the application of fibre-reinforced polymer (FRP) bridge decks for use in highway bridges and to produce design requirements and guidelines for FRP bridge deck systems. The research included verification, through tests on a full-scale glass FRP bridge deck under dynamic wheel loading. The conclusions, that FRP can provide adequate service performance on fatigue, were used to formulate design guidelines and other issues relating to design, construction and maintenance of FRP bridge decks.

10.45 - "Fibre-reinforced Polymer Composites in Civil Engineering Structures"
Mr. Willem Souren - CLC-CUR Foundation, The Netherlands

The Centre of Lightweight Structures TUD-TNO, by assignment of the Dutch Ministry of Transport, Public Works and Water Management has designed a composite draw bridge (figure1). The bridge has been designed using composite Design Rules derived from several design codes and (testing) experience.This presentation presents these Design Rules, that fit into the existing Eurocode design approach and enable designers to apply Fibre Reinforced Plastics in Civil Engineering Structures. Applications of the Design Rules to a bridge(deck) design are shown. Important issues for bridge(deck) designs which cannot be fully predicted as yet, like impact, interlaminar shear fatigue, mechanical and adhesive joints and fire retardance are adressed showing experimental results.

Personal Resumé

Willem Souren graduated at the Technical University of Delft, Faculty of Civil Engineering in 1984. After his military service he started working at the Netherlands Organisation for Applied Scientific Research TNO, Division Industrial Technology in 1986. At the Centre of Lightweight Structures TUD-TNO he has been involved in the design, production and testing of fibre reinforced composite products like bridges and boats from 1996 up to now.

11.05 - Coffee Break on Sponsor Display Area

Session B Research

11.35 - "Failure analysis of composites – state of the art and recent developments"
Mr. Martin Knops - Institute of Polymer Processing, Germany

A reliable failure analysis is essential for any lightweight construction. In composites the prediction of the failure mode is as important as the calculation of the failure limit itself. The so-called “World wide failure exercise” has revealed recently the shortcomings of the methods and criteria widely used in engineering praxis. The winner of the Exercise is the so called “Puck-criterion” due to its accuracy in predicting failure limits and – even more important – due to its capability to predict the right failure mode. The knowledge of the failure mode is decisive for evaluating the danger of the calculated failure regarding the integrity of the whole composite part. Besides, just the knowledge of the failure mode enables the designer to adjust the right design keys for improving the failure behaviour of the component under focus. This lecture gives an overview about state of the art failure analysis and tools making the best criterion available for designers.

11.55 - "Analytical and experimental evaluation of aluminium bridge deck panel"
Mr. Tomasz Siwowski - Rzeszow University of Technology, Poland

Aluminium has a long record of performance for new or rehabilitated bridges worldwide. Bridges with aluminium decks or superstructures were first built in the 1940s. Now over 50 aluminium bridges have been built in Europe and the number is increasing. Since aluminium is lighter then steel and concrete, does not rust or need painting or protective coatings, and lower fabrication and installation time – hence lower cost – aluminium has distinct advantage on other construction materials. The Rzeszow University of Technology initiated a study to evaluate the aluminium deck system to be used in Polish Bridge rehabilitation programme. The first phase of this project analysed the static response of 2,60 x 4,00 m deck panel. The detailed stress analysis was carried out using a 3-D FEM computer model of the deck. The ultimate load test was performed on the panel at the laboratory. The analytical and experimental evaluation of the ultimate static test is the subject of the paper.

12.15 - "Experimental analysis of shear connection between steel and lightweight concrete"
Mrs. Isabel Valente - Universada do Minho, Civil Engr. Dept, Portugal

Lightweight concrete has had a decisive role in the construction of important structures. Recent technological developments have turned it into a competitive option for the construction of composite bridge decks. Steel and concrete have to work together in a composite structure. Connection the two materials is achieved by using steel connectors, having different shapes. Beside the commonly used studs, Perfobond connectors and T connectors are adequate when dealing with high strength concrete. Experiiments carried out by Oguejiofor (1994), Galjaard (1999), Hegger and Sedlacek (2000), Ferreira (2000), Machacek and Studnicka (2002) described and analysed the steel to concrete connection properties primarily on normal density concrete, both normal and high strength. This paper describes the tests carried out at the University of Minho using shear Studs, Perfobond rib and T connectors with lightweight concrete, following the EC4 recommendations.

12.35 - Buffetlunch

Session C: Engineering Design and Engineering

14.00 - "Design of a Composite Draw Bridge"
Mrs. Liesbeth Tromp - Centre of Lightweight Structures TUD-TNO, The Netherlands

The Center of Lightweight Structures TUD-TNO, by assignment of the Dutch Ministry of Transport, Public Works and Water Management has designed a composite drawbridge. In the design a steel upper lifting structure has been combined with a full composite bridge deck. It is a class 45 bridge (up to 150kN-axle load) with a span of 10 m and a width of 3m located the Zuid-Willemsvaart (the Netherlands). Aim of the development is a safe highly loaded composite structure that can be manufactured cost effectively by means of a resin infusion process. Motivation for the Ministry is to achieve reduced maintenance costs and to learn about composite materials in civil structures. The paper presents the resulting structure and explains the design process with the fail safe design philosophy.

14.20 - "Fiber-reinforced polymer decks for bridge systems: stiffness and strength"
Mr. Aixi Zhou & Mr. John J. Lesko - Virginia Polytechnic Institute & State University Blackburg, USA

The research presented here investigates the stiffness and strength characteristics of the multi-cellular FRP bridge deck systems consisting of pultruded FRP shapes. A closed form systematic analysis procedure was developed for the stiffness analysis of multicellular FRP deck systems. This procedure uses the Method of Elastic Equivalence to model the cellular deck as an equivalent orthotropic plate. The procedure provides a practical method to predict the equivalent orthotropic plate properties of cellular FRP decks. Analytical solutions for the bending analysis of single span decks were developed using classical laminated plate theory. The analysis procedures can be extended to analyse continuous FRP decks. It can also be further developed using higher order plate theories. When examining strength several failure modes of the cellular FRP deck systems were recorded and analysed through laboratory and field tests and Finite Element Analysis (FEA).

14.40 - "FRP Bridge Decks, from Design and Characterization to Field Implementation"
Professor Vistasp M. Karbhari - Department of Structural Engineering University of California, United States

Fibre reinforced polymer (FRP) bridge decks have immense potential for use both as replacement for deteriorating and sub-functional conventional decks and in new construction. Because of costs associated with the use of these materials care must be taken in the development to truly optimise the anisotropic nature of FRP. This paper discusses the development of a range of deck systems, provides results of extensive laboratory characterisation and FEA and then provides examples of current use in the field. A detailed case study describes the system through construction of a bridge along a major highway. Results of load testing after construction over a period of 2+ years at periodic intervals are provided as part of the implementation of a health monitoring system. The use of wireless telecommunications for remote monitoring is also discussed.

15.00 - "A new bridge deck for the Kaag Bridge; the first CRC application in civil infrastructure"
Mr. J. Blom & Mr. N. Kaptijn - Ministry of Transport and Public Works and Water Management, The Netherlands

Very high strength concrete (cube strength 180 Mpa) panels replaced an existing azobe wood bridge deck. It concerns 2 bascule-moving brides in the number 44 motorway near Sassenheim, The Netherlands. The longitudinal steel girders have a 685-mm axle distance.
Each bridge deck consists of 4 panels 7,25 x 2,95 m. In order to keep the maximum weight under 170 kg/m2 the CRC principle was used. This means very slender, very high strength concrete construction parts, combined with a high percentage of reinforcement. In this case the panels are 45 mm thin with 3 layers ø8-40 mm reinforcement (5.6%). The edges are 65 mm with 10% reinforcement.

15.30 SITE VISIT Bus tour + Boat Tour Rotterdam area. Visit to Kaag Bridge and several other bridges.

Excusion to Kaag bridge, followed by Boat Trip from Hook of Holland to Rotterdam whilst viewing several bridges in Rotterdam area. Conference dinner on board whilst sailing. Trip ends 22.30 hrs.

Excursion, boat trip and dinner are included in the conference fee.

FRIDAY 28th March, 2003

09.00 Registration & Coffee served in Sponsor Display Area

Conference Chairman: Mr. Peter Head - Faber Maunsell, UK.

09.30 Opening Conference

Session D: Case Stories

09.30 - Key Note Speech "Advanced Composite Bridge Decking System"
Dr. Sam Luke - Mouchel, UK (sponsored by Owens Corning)

10.00 - "High Strength Steel in the Erasmusbridge, Rotterdam"
Mr. Ir. K. Noorlander - Rotterdam Engineering Bureau, The Netherlands

The Erasmusbridge consists of a, steel, cable stayed bridge (277 m), and a basculebridge (span 55 m) crossing the "Nieuwe Maas" in the centre of Rotterdam. The bridges have orthotropic decks with a 8 mm wearing surface.
The design has been preceded by more than 40 years of experience with design and maintenance of orthotropic steel bridge decks.
The paper gives an oversight of the deckconstruction of the steel deck bridges of the last 40 years, a review of the development of thin wearing surfaces, as well as a detailed description of the design of the Erasmusbridge, the application of TM and high strength S460 steel and the experiences with the bridge after the completion in 1996 with the deck construction and the behaviour of the stays.

10.20 - "Fatigue aspects of orthotropic steel decks"
Mr. Leendertz - Ministry of Transport, Public Works and Water Management, NL.

Over recent years, steel bridges have evolved from an-isotropic steel structures to orthotropic structures. Deck plates were integrated into the total structure. Consequently the deck not only must accept direct traffic loads, but also the stresses and strains from the total structure. Analyzing fatigue damage, caused by traffic loading -and in many instances traffic over-loading- has lead to interesting conclusions how to detail the structure. Future designs can benefit from this work.

10.40 - "Fiber-reinforced polymer lightweight bridge"
Prof. Dr. Gerhard Sedlacek & Mr. Heiko Trumpf - Institute of Steel Construction and Light Weight Structures, Germany

There is a demand for light weight emergency bridges that are suitable for air transport, hand erection by unskilled workers and may be used for light support vehicles for humanitarian services.
The Institute of Steel Construction at the RWTH Aachen has been awarded a project to develop an economical solution for such single lane bridges for a span length of 20,0 m and MLC12-loads.
This lightweight emergency bridge has to be designed with particular regard to the mobility (low weight and volume for transportation by air) and flexibility (low technical effort, modular design, easy construction). Besides these requirements the sufficient lifetime (fatigue resistance) and maintenance (upkeep costs) have to be considered.
In order to compare different ways of construction and material various concepts have been developed and built including high strength steels, high strength aluminium alloys, high strength cold formed steels and glass-fibre-reinforced-polymers.
The presentation presents the design, the testing programme and the detailing of the glass-fibre-reinforced polymer bridge with bolted connections that uses semi-finished pultruded products as commonly available on the market.
A particular feature of the new lightweight concept is the sufficient robustness for execution and dismantles, cost effectiveness and durability in use that shall be realised by the following means:
- Total dead weight for the truss of 3,5 t plus 1,6 t for the deck out of glass-fibre-reinforced profiles,
- Development of FRP-deck elements coated with a primer and scattered with minerals,
- Modular construction of segments with a length of 4000 mm and a width of 3900 mm,
- Development of discountable bolt adhesive connections.
The first prototype of the bridge out of FRP with a length of 20 m has already been built and successful tested.

11.00 - Coffee Break on Sponsor Display Area.

Session E: Markets and Market Development

11.30 - Key Note Speech "Overview of Fibre-reinforced Composite Bridges in the United States and Implications for European Market Development"
Mr. Grant Godwin, Martin Marietta, United States

This paper would present an overview of fibre-reinforced composite bridges and bridge decks in the United States since 1995 with emphasis on the trends in increasing size, complexity and geographic/traffic volume placement. The paper would cover the early initiatives in RTM'ed deep draft bridges, pultruded/ RTM'ed decks and early stage girders progressing through current technology. The paper would emphasise current markets and projected trends/volumes. The closing section would focus on implications for development of the European composite bridge deck market. The paper would not be supplier specific.

11.50 - "Environmental considerations for structural for a bridge material selection"
Mr. Ryszard A. Daniel - Msc Ceng. Ministry of Transport and Public Works and Water Management, Civil Engr. Div. The Netherlands

Concern about environment presents a growing challenge for the engineers. An important issue in this matter is the environmental impact of structural material selection. The government of the Netherlands recognizes this by stimulating the research, and promoting environmentally favorable materials and technologies. One of the problems is a choice of an objective evaluation method. Environmental analyses comprise many issues that are not comparable, vague determined and sensitive to arbitrary assumptions. The evaluation method discussed in this paper presents an answer to this problem. It was first applied to evaluate a number of material options for a pedestrian bridge in the Noorland inner harbor, Province of Zeeland. Some more material options have been considered for the purpose of this paper. The analysis proves to be especially useful in early stages of structural design, when the number and the accuracy of the available data are limited. The most advantageous material for the Noorland pedestrian bridge appeared to be pultruded FGRP sections. The contracting and execution of this project are briefly discussed, followed by some concluding comments on future developments.

12.10 - "Aluminium Bridge, aluminium bridge decks"
Prof. ir. F. Soetens & Dr. ir. IJ.J. van Straalen - TNO Building and Construction Research, The Netherlands

Applications of aluminium have grown considerably in building and civil engineering the last decade. In building and civil engineering the increase of aluminium applications is due to various aspects like lightweight, durability and maintenance, use of extrusions, and esthetics. The paper starts with a short history of aluminium bridges and then focuses on aluminium bridges in the Netherlands. The design of 58 bridges for an international contest in 1998 is dealt with, which was the beginning of renewed interest in aluminium bridges. As a result several aluminium traffic bridges and a number of pedestrian bridges were built. In 1999 a three-year joint industry project was started which aims at further stimulating the use of aluminium bridges. Results of that project will be highlighted.

Personal Resumé

Prof. Soetens has a large experience with the design and calculation of aluminium structures, research, knowledge transfer and consulting. He is technical secreatry of the Dutch Aluminium Code NEN 6710 and chairman of Project Team 2 Connections of the Eurocode Aluminium.
Dr. Van Straalen has a large experience with novel joints and structural material applications and is an expert in fatigue and in adhesive bonded joints. His is a member of the Dutch Adhesion Society of the Bond van Materialenkennis.

12.30 - "Slow Burner, turning a bridge innovation into a commercial product"
Mr. Peter Head - Faber Maunsell, UK.

The paper describes a framework for successful delivery of innovation in construction, which can be used internationally, giving examples of how fibre reinforced composite applications have been realised using these methods. The paper explains how difficult and slow this has been and emphasises that there is a lack of commercial incentive for business to innovate. Public procurement methods in construction do not easily accommodate new ideas and technology. Indeed once a solution is patented it can actually stop it being used. This compares with other industries where innovation is welcomed and investment in Research and Development is therefore much higher.

13.30 - Lunch

14.30 - End of Conference (departure of Delegates)