Professional Documents
Culture Documents
2 J u n e 2003
Consequently, maintenance and reinforcement must be undertaken for these bridges to ensure extended service. The IS panel method developed by ISMIC and IHI is applicable to reinforcement of RC (reinforced concrete) deck without traffic control. This method has been applied to 25 bridges up until 2000. The Hyogo Viaduct repair work was a typical project conducted for the Ministry of Construction (present Ministry of Land, Infrastructure and Transport). The construction outline of the viaduct is described together with the effectiveness of RC deck reinforcement which was confirmed by the site load tests.
1. Introduction
Number of bridges
250 000 200 000 150 000 100 000 50 000 Service of 50 years and longer Service of 75 years and longer Total number of bridges
Road structures are increasingly being damaged by increased automobile traffic, larger vehicles, and aging, and there are many steel bridges with seriously damaged RC deck. The IS panel method is among several methods used for repairing/reinforcing damaged RC deck but is especially applicable to seriously damaged RC deck and can be used for reinforcing them from the underside without the necessity of traffic control. As bridges in Japan face an ultra-high aging era increasingly requiring maintenance, we report the achievements of the IS panel method and work details of the Hyogo Viaduct, which was reinforced by this method. The IS panel method was developed jointly by ISMIC and IHI and obtained the technical qualification of the Road Management Technical Center in 1997. For the detailed design and execution method, see the reference.(1),(2)
0 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 2045 2050 Year
Fig. 1
existing bridges are left unattended, the number of unusable bridges will increase, thus impeding social activities. Replacing all the bridges 50 years or older is impossible because of national finances, so it is necessary to take measures to extend the life of the existing bridges by 50/100 years by repairing and reinforcing them now when the extent of damage is small. The IS panel method is also an effective method for prolonging bridge life.
V o l . 36 N o . 2 J u n e 2003
Table 1
Order issued by
Achievements by IS panel
Bridge name Asakaoohashi Nezugasekigawabashi Houmeikosenkyou Yamatobashi Nagakumaoohashi Kazanamibashi Naraoohashi Niyodogawabashi Tushimaoohashi Miyoshioohashi Daiichiichinosebashi Dainiichinosebashi Hyougokoukakyou Syoujinbashi 16 goukyouryou Koutoushinbashi Kasaibashi Takaidorikkyou Harumibashi Aritakosenkyou Anzaibashi Tannanbashi Yoshinoguchikosenkyou Ondooohashi Oyatanibashi 25 bridges Year 9 10 12 6 11 7 5 7 7 10, 11 12 12 11, 12 11 12 6, 8 8 9 12 5, 6 7, 8, 9 8 10 8 11 Area (2) 44 411 213 687 22 375 1 193 2 163 346 1 412 481 516 640 447 72 491 1 058 21 1 400 596 1 768 517 320 1 032 295 16 520
Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ministry of Land, Infrastructure and Transport Ibaraki Prefecture Gunma Prefecture Tokyo Metropolis Tokyo Metropolis Tokyo Metropolis Tokyo Metropolis Niigata Prefecture Shizuoka Prefecture Osaka Prefecture Nara Prefecture Hiroshima Prefecture Water Resources Development Corporation Total
Side view
340 225 17 025 9 17 000=153 000 13 875 25 000 25 000 21 300 4 17 000=68 000 17 025
A1
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
A2
Plan
17 025
25 000
25 000
17 025
IS panel
G1 1 050 G2 G3 G4 1 250 G1 1 050 G2 G3 3 3 300=9 900 3 3 300 = 9 900
Fig. 2
V o l . 36 N o . 2 J u n e 2003
Fig. 3
General view
Effective width Total width Number of main girders Main girder spacing RC deck
For this bridge, RC deck reinforcing had been done by the underside thickness increasing method, but this time the IS panel method was adopted for RC deck reinforcing work as a pilot project based on a general judgment on the extent of damage of RC deck, durability, work cost and environmental impact compared with other methods. For reinforcing the existing RC deck from the underside, such methods as shown in Table 2 are available. The design and execution of RC deck reinforcing work by the IS panel method for the Hyogo Viaduct are outlined below. 4.2 Design and structure The design conditions when the IS panel was designed are as follows. (1) The IS panel is designed for RC deck reinforcing. (2) The IS panel is loaded with dead load and live load. (3) The live load is B live load, the rear wheels of the automobile are of two axles and the wheel load is 5 tf. (4) The load is distributed at 45 from the top surface of the existing RC deck and works on the IS panel.
Reinforcement
Method to decrease 1. Load distribution factor is improved. stress by reducing stress 2. If cracking density increases, shear resistance decreases. resultant 3. Even when stress level decreases, cracking progress does not stop. Method to reduce stress by increasing sectional rigidity 1. Combining effect with existing RC deck is high and flexural rigidity increases. 2. Shear resistance is recovered due to penetration of resin into cracking. 3. Another method must be considered for RC deck of cantilever portion. 4. If rainwater is accumulated, separation from the existing RC deck may occur and bonding effect may decrease. 1. Concrete theory is established with the thickness increased portion and the existing portion as one piece, and rigidity against bending and shearing is improved. 2. Another method must be considered for RC deck of cantilever portion. 3. Any deterioration of concrete cover must be removed. 4. New cracking tends to be induced by vibrating drill. 1. It is not so easily affected by the shape of RC deck underside and additive. 2. Work execution is easy. 3. Rate of increase in dead load is very small. 4. Another method must be considered for RC deck of cantilever portion. 5. Any deterioration of concrete cover must be removed. 1. Method to compensate for re-damage in stringer extension method. 2. It is effective when running cost is high. 3. If the combination method is to be adopted in the first place, there may be other methods superior in economy, reinforcing effect, durability, and appearance. 1. Since panels are supported by main girder, deflection and stress are greatly reduced and reinforcing effect is high. 2. No dropping of concrete pieces and no dropping of block. 3. RC deck of cantilever portion can also be reinforced by adopting a structure using stringer and bracket. 4. Rigidity on flange side on main girder becomes very high, and as a result, the stress of flange side on main girder is reduced. 5. Rate of increase in dead load is higher than other proposal. 6. If the RC deck underside is rough, the quantity of filling material increases. 7. Cost of re-painting the panels is incurred.
Medium
Medium
Medium
Medium
Medium
Small
Combination of stringer extension and steel plate bonding or underside thickness increasing or carbon fiber sheet attaching method
Method to reduce stress by decreasing stress resultant and increasing sectional rigidity at the same time Method to reduce stress by decreasing stress resultant and increasing sectional rigidity at the same time
Large
Large
IS panel method
Large
Large
118
V o l . 36 N o . 2 J u n e 2003
(5) The rigidity of the existing RC deck is expected, and the load is shared by the existing RC deck and the IS panel. (6) RC deck of the portion surrounded by the main girder and cross girder is reinforced by the IS panels. (7) In the axial direction of bridge, the IS panels are separated at the cross girder and are not made continuous. (8) The haunch portion of RC deck is not reinforced. (9) The clearance between the IS panel and the existing RC deck is filled with epoxy resin. Based on the above design conditions, the IS panels were designed in the following structural dimensions. Main girder spacing (cross rib span length) 3 300 mm Cross rib spacing (longitudinal rib span length) 1 565 mm Longitudinal rib cantilever length 367 mm
Longitudinal rib spacing 384 mm Pavement thickness (asphalt) 50 mm RC deck thickness (reinforced concrete) 210 mm Deck plate thickness of IS panel 6 mm Longitudinal rib section 130 10 mm Cross rib section Web 420 8 mm Flange 100 8 mm Fig. 4 shows the structural drawing of the IS panel. As a result of the design calculation, the unit steel weight of the IS panel was 853 N/m2 {87 kgf/m2}, and we think that a rational design was made because the target was 980 N/m2 {100 kgf/m2} or less. 4.3 Execution of work The IS panels were manufactured at a factory Fukuoka Prefecture and transported in two lots to the site by a 30 t truck at night. Under the bridge at the erection site, were flat ground and an agricultural pond. Under such topographical conditions, the erection of IS panels
410
88
6 384=2 304
3 300
2 480
Drain hole 737 200 40 330 367 1 500 1 500 3 727 1 500 1 500 400.5 500 100 40.5 40 360 360 1 565 1 565 3 857 1 565 1 565 507.5 40.5 100 367
100
R2
.5
10
28 drill
60 124 99.3
420 8
420
351 170 60 75
3 20 185 15
G2 G3
O 15 185 20 9
G1 G4
2 875
Outside diameter
40
27.2
15
40
3 300
Fig. 4
119
V o l . 36 N o . 2 J u n e 2003
Crane
Moving truck
G.L
Member taken in Member transporting procedure (direction normal to bridge) section Temporary pedestal (Prefabricated scaffolding) Boarding protection Trolley for 1 t
Trolley for 1 t
Chain block
Rail for trolley Member transporting procedure (direction normal to bridge) side Rail for trolley Trolley for 1 t Lever block for 0.5 t
Member transporting procedure (bridge axial direction) side Lifting ring for 2 t Rail for trolley
Fig. 5
Erection procedure
120
G.L
Fence removal/restoration
V o l . 36 N o . 2 J u n e 2003
was made as follows. (1) Flat ground under the bridge Erection members were moved to a specified place by truck. The member was raised at 4 points by chain block, positioned, and then connected to the main girder with high-strength bolts. (2) Place with retarding basin under the bridge Suspended scaffolding is installed. Load-taking section is provided with prefabricated scaffolding. Under the main girder and cross girder, rails for trolley were installed. The member lifted at the load-taking section by the trolley is laterally moved to the specified position in the axial direction of the bridge and in the direction normal to the axial direction of the bridge. The work to lift the member at the specified position and install it to the main girder was the same as the erection method on the flat ground. The erection proceeded as scheduled and was completed within the construction period as expected. In the reinforcing method from the underside of RC deck, including the IS panel method, it is important to stop penetration of rainwater from the cracked portion of RC deck. Such penetration will not only damage RC deck but also allow the water to accumulate on the top surface of the member reinforcing RC deck, weakening the adhesion between the existing RC deck and the reinforcing member. For this bridge, a waterproof layer had already been laid under the pavement and the IS panel was provided with a drain pipe so that no rainwater would accumulate between the reinforcing member and RC deck. Fig. 5 shows the erection procedure of the IS panels, Table 3 shows the schedules of the site work and Fig. 6 shows the condition after reinforcing. 4.4 Tests to check reinforcing effects To check the effects of RC deck reinforcing by the IS panel method, we conducted static loading tests as follows before and after the reinforcing. (1) The purpose of the tests was to check the effect of reducing the stress of the reinforcing bars of the existing RC deck and the difference between the calculated stress and measured stress of the IS panel. (2) As a loading load, a 25 tf dump truck (tandem type) was used, and the test was repeated 3 times to measure the static deformation, paying attention to the longitudinal rib and cross rib with two IS panels. Fig. 7 and Table 4 show the loading positions and test results, respectively. The results confirmed that the stress of the main reinforcing bar of RC deck decreased
Table 3
Item Preparatory work Design checking, procurement for materials Temporary equipment work Site measuring Panel fabrication at factory Transporting RC deck surface preparation Erection work of panels, etc. Seal, filling work Field painting
Fig. 6
to about 1/5 of the stress before the reinforcing and the reinforcing effect. With the cross rib of the IS panel, the measured stress was 16% against the calculated stress, proving that the structure was within the calculated values. The deflection of the entire bridge measured at RC deck center decreased to about 75% from the deflection before the reinforcing, and it was verified that the rigidity of the entire bridge, including the load distribution effect, increased.
5. Conclusion
We have described the necessity of maintenance of steel bridges in Japan and the features of the reinforcement of existing RC deck by the IS panel method and reported on the application of this method to the Hyogo Viaduct. We hope this method will be used for reinforcing RC deck of steel bridges in the future, thus contributing to the improvement of permanent durability of the bridges. We are now striving to develop more economical structures with improved
121
V o l . 36 N o . 2 J u n e 2003
Loading point A2
Loading point B2
Loading point A1
Loading point B1
3 300 G4 Distribution reinforcement direction Main reinforcement direction Deck plate Longitudinal rib
Loading point B2 Deck plate Loading point B1 Longitudinal rib 50 To Takeo 192 50
To Tosu
Fig. 7
Loading position
Structure
Member name
Measuring position
Gauge No.
Stress measured Stress measured Stress measured Stress measured Calculated stress after reinforcing before reinforcing after reinforcing after reinforcing Stress measured N/mm2 { kgf/cm2 } N/mm2 { kgf/cm2 } N/mm2 { kgf/cm2 } Calculated stress before reinforcing 13 {108} 57 {547} 57 {547} 136 {1 361} 13 {108} 57 {547} 57 {547} 136 {1 361} 16 {156} 3.08 mm 22 {217} 3.20 mm 3 {32} 2.40 mm 4 {42} 4 {42} 4 {40} 22 {216} 3 {25} 2.30 mm 4 {36} 5 {45} 4 {41} 23 {221} 0.39 0.08 0.07 0.16 0.33 0.08 0.07 0.16 0.21 0.78 0.12 0.72
RC deck Main reinforcement reinforcing bar Deflection RC deck center Bridge axial direction
Reinforcing member
Deck plate Direction normal to bridge axis Cross rib RC deck reinforcing bar Main reinforcement Deflection RC deck center Bridge axial direction
Reinforcing member
workability, for example, by using weathering steel in consideration of the LCC (Life Cycle Cost). We were able to complete RC deck reinforcing work of the Hyogo Viaduct with the help of guidance and suggestions from the staff of Saga National Highway Construction Office, Kyushu Maintenance Bureau, Ministry of Land, Infrastructure and Transport. We express our heartfelt thanks to them.
REFERENCES (1) Road Management Technical Center : Report for Examination and Certification of Road Maintenance Technology, IS Panel Road Maintenance System, March 1997 (2) T. Ishii, M Sugizaki and M. Iida : IS Panel Under Deck Panel Method Underside Reinforcement Method for Reinforced Concrete Slab of Steel Bridge, Ishikawajima-Harima Engineering Review Vol.37 No.6 Nov. 1997 pp.470-473
122
192