PEC-4072B

COMPOSITE MATERIALS HANDRAIL TESTING

Interested Party: Cogumelo Indstria e Comrcio Ltda Fiberglass
Pultruded Products






COPPE Program: Civil Engineering







Project Coordinator: Eduardo de M. Batista








March 2003



PEC-4072B

1. Introduction

This document includes a technical report describing the tests carried out on the industrial handrail
structural performance in accordance with COPPETEC PEC-4072 proposal, dated 15 October,
2002.
The tests were performed at the COPPE/UFRJ Structural Lab on 18 November, 2002, 21 January
2003 and 31 March 2003.

2. TEST DESCRIPTION

The procedures required for the tests were established by the Interested Party as follows:

Tests required by HPL for Platforms P-43/P-48
The three basic tests required are: horizontal static load, vertical static load and horizontal dynamic
load:
A) Horizontal Static Load: Three point loads (F) applied simultaneously to the top span of the
handrail. F is equal to 600N/m and the three load points are the following: F4 placed at 0.25L; F2
at 0.5L and F4 at 0.75L. After three minutes, the permanent deformation allowable is 8H/1000,
where H is the height from the top of the handrail to the top of the deck;
B) Vertical Static Load: 1000N total force applied to two load points (500N) placed at 150mm
from each side of the central span. After three minutes, the permanent maximum deformation
allowable is 3mm.
C) Horizontal Dynamic Load (applied horizontally to the top rail): Application of a 180 Joules
load by dropping a Weight: 90kg; Height: 0.204m onto the handrail section, via cable and pulley.
Vertical post maximum deformation allowable amounts to 200mm while the weight is still applied.


Attached is a copy of the document provided by COGUMELO (Interested Party) indicating which
experimental procedures should be followed in order to confirm the aforementioned data. The
testing equipment was provided by the Lab and the applicable results are described below.

The load was applied vertically on the handrail upper section. The deformation of the handrail
section was measured and recorded immediately after the removal of the load from the handrail.
Overall condition of the columns, as well as the structural integrity of the handrail sections were
observed prior to, during and after each load application.
PEC-4072B

3. GUARDRAIL PROTOTYPE TESTED

In order to conduct the tests, the Interested Party (COGUMELO) furnished two guardrail prototypes
manufactured with square section (5x5cm) tubes made of pultruded FRP in phenolic resin. Brown
is the color of the guardrail finishing and its dimensions are shown in Figure 1.

Shapes were secured to a U steel profile (height=254mm; weight= 22.7kg/m; thickness= 6.1mm)
previously fixed to a rigid metallic structure as shown in Figure 1 and attached photos. The
installation system established by COGUMELO as shown in Photo No.4 consists of 2 bolts per
post. To prevent the handrail sections from falling apart prior and during the compression tests,
each section of handrail was secured to a steel support by using two drilling screws on each side
of the sections


4. RESULTS ACHIEVED

4.1 Horizontal Static Load Test

The test completed on 18 November, 2002 was conducted in the presence of the following
Interested Party representatives: Mario Colao (Halliburton) Luiz Claudio Gonalves, Leonardo
(ABS) and Glauco Ribeiro (CENPES/Petrobrs).

The handrail section was horizontally loaded with three loads as shown in Figure 2. The loads
corresponded to a static loading equivalent to 600 N/m distributed along the upper part of the
handrail system, as follows:

Load on the upper part of the central post: F
1
= 600 x L/2 = 600 x 2.42/2= 720 N (corresponding
load equal to F
1
/9.82=73kg)
Load on the center of the span: F
2
=600 x L/4 = 600 x 2.4/4 = 360 N (corresponding load equal to
F
2
/ 9.82 = 37kg)

The loads were previously measured in the presence of the Interested Party representatives. The
results achieved can be checked in the table below:


PEC-4072B

F
1
= 75.2 kg x 9.82 = 728 N
F
2
= 36 kg x 9.82 = 354 N

The proper equipment analyzed the horizontal deformation on the upper part of the central post F
1,
and the rotation produced to the metal profile to which the handrail was secured. For this purpose,
a deflectometer with 10
-2
reading sensibility on the top of the central post and two deflectometers
with 10
-3
reading sensibility inside the hollow of the steel U profile were installed. This equipment is
shown in Figure 2.

The testing procedure is as follows:

Initial Step: Zero load, initial reference reading
100% Load Step: Total load, no reading
Final Step: Readings: three minutes after the weight impact

Below, the results achieved:

Step F
1
(10
-2
mm) F
2
( 10
-3
mm) F
3
(10
-3
mm)
Initial 3400 0742 4627
100% Load - - -
Final (3 minutes) 3050 0786 4627
Displacement (mm) 3.50 0.044 0.000


The permanent maximum displacement allowable after the three-minute period subsequent to the
weight drop and taking into consideration the height (H) measured = 1100mm:

d
max
= 8.H/1000 8 x 1100/1000 = 8.80mm

Therefore, the total displacement achieved in the test (even disregarding the torsion rotation of the
U steel profile) is within the limits deemed allowable.

d
max
= 3.5mm < d
max
= 8.80mm


PEC-4072B

The guardrail prototype was approved in the horizontal static load test

4.2 Vertical static load test

This test was conducted on 21 January, 2003 in the presence of the following Interested Party
representatives: Salsio Schuelter (Cogumelo), Lus Cludio (ABS), Mrio Colao (Halliburton),
Mrio Canedo (Suprimar / Mau Jurong) and Glauco Ribeiro (CENPES/ Petrobrs).

The vertical static load test was conducted with two 500N loads, each one displaced 150mm from
the center of the handrail spans. Photo No.1 shows the test in progress.

The readings at the central point of the loaded span arrow were taken from a Mitutoyo dial
indicator with 10
-2
reading sensitivity.

The reading results are the following:


Readings Steps Measured values (10
-2
mm)
Initial reference reading, zero load. 2091
100% load 1925
Zero load after three minutes 2085
Final arrow after three minutes 0.06


Considering that the permanent arrow maximum allowable value is 3mm, the guardrail prototype
was approved in the static vertical load test.

4.3 Dynamic horizontal load test

This test was conducted on 31 March, 2003 in the presence of the following Interested Party
representatives: Salsio Schuelter (Cogumelo), Lus Cludio (ABS), Mrio Colao (Halliburton),
Mrio Canedo (Suprimar/MauJurong) and Glauco Ribeiro (CENPES/ Petrobrs).



PEC-4072B

The test consisted of a concentrated load created by the 204mm course fall of a 90kg load and
placed on top of the central column. This load corresponded to the potential force of F=90 x 9.82 x
0.204=180.3 Joules. The equipment used in this test is shown in Figure 3. The free fall started
immediately after the bowknot wire was cut. The course of the free fall was controlled by a steel
cable from the Lab rolling assembly, which was previously secured to the loading system.

The 91.2kg load application was carried out by using a set of weights previously measured in the
presence of the Interested Party representatives. The length of the free fall course was 20.5cm
measured with a measuring tape (this measurement was taken by positioning the weight height
after being suspended with the rolling assembly cable). Therefore the impact load corresponded to
a potential force of: F= 91.2 x 9.82 x 0.205 = 183.6 Joules.

The horizontal deflection measurements on top of the central post were taken with a metallic
measuring tape graduated in mm and evaluated against a fixed reference post, independent from
the prototype.

After the impact of such weight, the prototype remained fixed to the steel profile. Photographs of
the test are attached herein.

Also after the impact, the fixed connectors remained intact, showing no signs of structural
degradation. The 32mm horizontal displacement was measured on top of the central rail while still
bearing the weight applied of 91.2kg.

Considering the 200mm maximum allowable displacement value obtained, we can well conclude
that the guardrail prototype was approved in the dynamic horizontal load test.

5. Conclusions

The FRP composite materials handrail prototypes were approved in the three tests proposed.






PEC-4072B


ANNEX 1: Figures



Figure 1: Chart of the handrail prototype secured to a steel U profile.
Installation: 2 bolts, d=10
Steel U profile: 254 x 22.7

PEC-4072B





Figure 2 : Chart of static horizontal loading and equipment system to measure
displacements.


PEC-4072B






Figure 3: Chart of the dynamic horizontal load test
Weight= 91.2kg
Free fall =20.5cm



PEC-4072B


ANNEX 2: Photos



Photo No.1: Vertical static load test set up


PEC-4072B



Photo No. 2: Dial indicator (reading sensitivity= 10-2mm) for measurements during vertical
static load tests.

PEC-4072B


Photo No. 3 Chart of the horizontal dynamic load test

PEC-4072B




Photo No. 4: Securing system with two screws, d=10 per post.

PEC-4072B




Photo 5: Final displacement measurement after load impact during horizontal dynamic load
test.
PEC-4072B


ANNEX 3: Documentation

Doc.1: Test specifications.

PEC-4072B

ANNEX 4: Evaluation of handrail test results with 1.5m maximum span
between posts (3m section)

The tests described in this document refer to 2.4m handrail sections. The sections tested
measured 3.0m (1.5m span between posts) therefore:

(a) Horizontal static load test

Correction of the load applied: F x 3/2.4 = F x1.25
Result obtained for the 2.4m span = 3.5mm
Correction of the arrow for the 3.0 span: 3.5 x 1.25 = 4.38mm < 8.8mm
Approved

(b) Vertical static load test

Correction of the measured arrow: F x (1.5/1.2)2 = F x 1.56
Result obtained for a 2.4m span = 0.06mm
Correction of the arrow for the 3.00m span: 0.06 x 1.56 = 0.09mm < 3mm.
Approved

(c) Horizontal dynamic load test

Result obtained for a 2.4m span: 32mm
Maximum value allowable: 200mm
Therefore, as the value measured equal to 16% of the maximum value allowable, the
increase of the guardrail spans from 2.4m to 3.0m, certainly will not produce an arrow that exceeds
200mm.
Approved

Therefore we may conclude that the handrail manufactured with FRP composite materials in
phenolic resin and presenting the maximum span of 1.5m between the posts was approved.




PEC-4072B



COMPOSITE MATERIALS INDUSTRIAL HANDRAIL TESTS


Rio de Janeiro, April 2, 2003



Project Coordinator



Civil Engineering Program Coordinator


COPPETEC Foundation CEO