PRESENTED BY 8 th International PIANCSMART Rivers Conference Pittsburgh PA September 20 2017 Piyush Soti Graduate Research Assistant Dr PV Vijay Assistant Professor Dept of Civil amp Environmental Engineering ID: 808111
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Slide1
FRP COMPOSITE STRUCTURES IN THE US INLAND WATERWAYS
PRESENTED BY:
8th International PIANC-SMART Rivers Conference Pittsburgh, PA, September 20, 2017
Piyush Soti Graduate Research Assistant
Dr. PV Vijay Assistant Professor
Dept. of Civil & Environmental Engineering
West Virginia University
Slide2Background & Introduction
Objective
FRP Wicket Gates
FRP Miter Blocks
FRP Recess Protection Panels
Conclusions & Recommendations
Design, Manufacturing, Field implementation
Slide3FRP composites are emerging as a solution for both rehabilitation and new construction.
The advantages with FRPs are:
high strength/stiffness to weight ratioresistance against corrosion, moisture, chemical attack excellent durability, low thermal expansion
enhanced fatigue and wear resistance FRPs offer potential for construction or repair of critical components of navigation systems at a reduced cost and greater durability.
Background: FRP Composites
Slide4The inland navigation system serves as a backbone to the nation’s economy carrying an equivalent of 51 million truck trips each year.
Many hydraulic locks and dams have not been updated since 1950s and have exceeded their design life.
The American Society of Civil Engineers (ASCE) has rated the nation’s inland waterways infrastructure as D-.
US Army Corps of Engineers spends almost 73% of their budget in repair and rehabilitation of current lock and dam facilities.
Background: Navigation Infrastructure
Slide5Introduction
Hydraulic structures are prone to severe corrosion and deterioration.
Corrosion leads to expensive repairs/maintenance, closure, and in some cases replacement of the hydraulic structures.
Traditional steel and timber used in navigation infrastructure deteriorate within 10-15years of service and require costly and periodic repair.
The USACE requires more than $13 billion by 2020 to keep navigation infrastructure functioning without additional damages. Due to budget cuts associated with the use of traditional materials, the USACE is exploring the use of FRP composites.
Slide6To engineer waterway structures with noncorrosive FRP composites to prevent extensive in-service maintenance and replacement.
Objective
Wicket gates
Miter blocks
Recess panel
Slide7DEVELOPMENT
OFFRP WICKET GATES
Slide8Introduction: Wicket Gate
It is a movable dam that can be raised in times of low water.
It is generally constructed of steel or iron frame with timber leaf.
It is hoisted into position with a gantry operated crane without utilizing any hydraulic cylinder.
Wickets are hinged just below their center point & held in an upward position with a prop which slides into a hurter track.
Slide9Deterioration of a timber wicket gate
Slide10Forces on wicket gate
The gate was analyzed in operating, resting, and lifting positions.
PositionProp forcekN
(kip)Shear force on gate section,
kN (kip)
Bending moment on gate section,
kN
-m (kip-
ft
)
Operating
(with tail water)
93 (20.9)
46.3 (10.4)
30 (22.1)
Operating
(without tail water)
102.3 (23)
40.9 (9.2)
27.7 (20.4)
Resting
0
0
0
Lifting
0
132 (29.6)
165.4 (122)
Wicket gate in operating position
Slide11FRP wicket gate section
A FRP section 1.17m (46”) x 216mm (8.5”) was selected with flange thickness of 13.3 mm (0.523”) and web thickness of 10.16 mm (0.4”). MI of a selected FRP module was 39,250.6 cm4
(943 in4). In addition, two steel plates were embedded inside face sheets to enhance moment of inertia, reduce deflection and buoyancy.
9.5 mm thick
steel plate
Slide12Bending of FRP wicket gate
FRP wicket gate was loaded in a 3-point bending with a span of 4.57 m and a central load of 89 kN. The max. deflection and tensile strain were14.81 mm and 978 µε, respectively.
The gate was fatigue tested at (53-107 kN) for 50,000 cycles and 3-point bending was performed with a load of 89 kN. The max. tensile strain was 975 µε as compared to 978 µε before fatigue loading.
The strain energy absorption capacity of the gate was not reduced after fatigue.
Slide13Field Installation
Four FRP wicket gates were installed in Mississippi River at Rock Island lock and dam, Illinois, USA in Fall 2015.
They are performing well without any signs of deterioration. About 2/3 the cost of timber gates on a first cost basis and expected life > 50 years (timber gate is ~15 years).
Slide14DEVELOPMENT
OFFRP MITER BLOCKS
Slide15Introduction: Miter Blocks
Miter blocks are installed in lock gates to form a watertight seal between two gate leaves during closure.
They are made of solid steel with a cross-section of 101.6 mm x 63.5 mm and lengths up to 13 m
Blocks have to withstand:wet-dry cycles, corrosive elements, mitering forces, and freeze-thaw effects.compressive stress of 9.65
MPa through its mitering surface 10,000 cycles of opening and closing operations in a year. Corrosion of steel blocks have been the cause of gate misalignment and potential lock closure.
Slide16Design of FRP miter blocks
Designs-A, and-B were fabricated using off-the-shelf FRP shapes.
Design-C was fabricated by bonding laminates and Design-D was manufactured by VARTM process.
Based on poor performances under compression and fatigue, Designs-A and -B were eliminated and design-C was eliminated due to its complexity in fabrication. Solid FRP section (design-D) was selected as a potential miter block for additional testing.
Design-C and Design-D
Slide17Compression and Fatigue Testing on FRP Block
FRP miter blocks were subjected to compression in all directions. The values were 379
Mpa
(55 ksi), 214 Mpa (31 ksi), and 165
Mpa (24 ksi).Blocks were also tested in fatigue with a load range of 8.9-48.9
kN
for 500,000 cycles and showed no signs of cracking.
Testing of these blocks showed that they have higher than required strength, stiffness, and ductility properties.
Slide18Performance of FRP Miter Blocks subjected to Water Immersion
Depending upon the height of the lock gate, FRP miter blocks can be subjected to not only moisture but also to water pressure.
FRP miter blocks were cut to smaller lengths and few specimens were coated with an epoxy, while others were not coated. Both coated and uncoated specimens were kept in a container filled with water at NTP and inside a water chamber pressurized to 15.5 MPa .
Slide19Performance of FRP Miter Blocks subjected to Water Immersion (Contd.)
After 60 days, specimens were tested for moisture absorption. The application of a resin coat on cut specimens helped in reducing the absorption of moisture.
The application of pressure resulted in an increase of 90-200% moisture ingress. Wet FRP blocks were tested in compression and were found to be lower but still above service requirement values.
Slide20Field InstallationWorkers were able to handle light-weight blocks and install them with ease.
Solid FRP block cost about $500 per meter length. With an expected service life of 50 years for FRP blocks, there will be savings in terms of materials, labor, equipment, and others.
FRP blocks were installed by bolting them to the existing lock gate at Hiram M. Chittenden Locks, Washington, USA in summer 2015.
Slide21DEVELOPMENT
OFFRP RECESS PANELS
Slide22RECESS PROTECTION PANELS
Recess panels are located in the upper lock approach and are used in many navigational structures. They are used to protect the recess areas in the lock chamber from barge impact damage to lock walls. The panels protect the recess area in the lock that allows the emergency gate to rise when miter gates are inoperable.
Current panels are 12” thick and made of welded 12WF45 steel I-beams, angles, and plates. Current steel recess panels are heavy to lift and corrode in a short time requiring regular corrosion resistant surface coatings.
Slide23DEVELOPMENT OF A FRP PANEL
The panels are supposed to be designed to withstand a barge impact load which when calculated required over 100 foot-kip section.Currently available off-the-shelf shapes are explored to develop FRP panels.23
SUPERPILE of 12” diameter and 0.5” wall thickness
Doubling 4” low-profile FRP composite cellular modules
Doubling 4” x 6” rectangular tubes
FRP SUPERDECK of 12”x 8”
Slide24DESIGN OF A FINAL FRP RECESS PROTECTION PANEL
Based on 4 different configurations evaluated, hexagonal deck was the best shape in terms of energy absorption.Crushing failure and moment capacity of the single FRP superdeck at a clear span of 96” was 48.4 kip and 96.8 ft
-kip, respectively. It was made with 12 FRP superdecks and edge steel channels. In the field, the impact force from the barge is distributed to several beams of the FRP panel system, thus carrying significantly higher loads.
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Slide25FABRICATION OF FRP RECESS PROTECTION PANELS
Twelve
pultruded
FRP superdecks and hexagonal shear keys were assembled by adhesive bonding.
FRP panel was housed in steel channel sections to facilitate smooth angles for ship and barge impacts.
Following the panel assembly, top surface was coated with 0.375” thick impact resistant polyuria resin.
Final dimension of the panel was 9’10.5” x 11’10”.
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Slide26TEST RESULTS ON FRP RECESS PANEL
The first test was performed with the application of load through 6” x 6” plate, placed at the center of the seventh hexagonal FRP beam. For 30 kip of applied load, the maximum deflection at center was 0.27” and the maximum bottom tensile strain was 880 micro-strains.
Load applied
(6” x 6”)
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Slide27LOAD DISTRIBUTION FACTORS
Beam no.
Def (in)LDF
LDF (%)
1
0.032
0.027
2.66
2
0.045
0.037
3.75
3
0.059
0.049
4.91
4
0.077
0.064
6.41
5
0.11
0.092
9.16
6
0.165
0.137
13.74
7
0.257
0.214
21.40
8
0.165
0.137
13.74
9
0.11
0.092
9.16
10
0.077
0.064
6.41
11
0.059
0.049
4.91
12
0.045
0.037
3.75
Beam
no.
Def (in)
LDF
LDF (%)
1
0.031
0.028
2.77
2
0.044
0.039
3.93
3
0.057
0.051
5.09
4
0.073
0.065
6.52
5
0.103
0.092
9.20
6
0.153
0.137
13.66
7
0.229
0.204
20.45
8
0.153
0.137
13.66
9
0.103
0.092
9.20
10
0.073
0.065
6.52
11
0.057
0.051
5.09
12
0.044
0.039
3.93
30 kip load with 6x48 plate longitudinal
30 kip load with 6x24 plate longitudinal
When the 30 kip load was applied longitudinally on the center beam with 24” long and 48” long spreader, the applied load was distributed to other beams.
Tables below show around 80% of the load being distributed to all other beams.
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Slide28LOAD DISTRIBUTION FACTORS (CONTD.)
Beam no.
Def (in)LDFLDF (%)
1
0.052
0.024
2.36
2
0.079
0.036
3.58
3
0.103
0.047
4.67
4
0.142
0.064
6.43
5
0.209
0.095
9.47
6
0.35
0.159
15.86
7
0.389
0.176
17.63
8
0.35
0.159
15.86
9
0.209
0.095
9.47
10
0.142
0.064
6.43
11
0.103
0.047
4.67
12
0.079
0.036
3.58
Beam no.
Def (in)
LDF
LDF (%)
1
0.05
0.023
2.35
2
0.08
0.038
3.76
3
0.107
0.050
5.02
4
0.148
0.069
6.95
5
0.228
0.107
10.70
6
0.313
0.147
14.69
7
0.328
0.154
15.40
8
0.313
0.147
14.69
9
0.228
0.107
10.70
10
0.148
0.069
6.95
11
0.107
0.050
5.02
12
0.08
0.038
3.76
60 kip load with 6x24 plate transverse
60 kip load with 6x48 plate transverse
When 60 kip load was applied transversely with center on 7
th
beam using 24” and 48” long spreader, the applied load was distributed to other beams of the panels.
Tables below show more than 85% of the load being distributed to all other beams.
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Slide29Conclusions and Recommendations
FRP wicket gates, miter blocks, and recess protection panels were successfully developed as replacements to conventional material-based structures with adequate safety factors against bending, shear, and fatigue. These structures were lighter, cost effective, easily fabricated and installed in the field. Regular monitoring and inspection of field implemented FRP structures will help in understanding their long-term performance, effectiveness, and durability for their mass implementation in hydraulic infrastructure.
Slide30Acknowledgments
This Work is Sponsored by USACE and the work is carried out by the WVU-CFC, Department of Civil and Environmental Engineering, Statler College, West Virginia University.Manufacturing coordinated and carried out in partnership with Composites Advantage Inc., Creative
Pultrusion Inc., and Fiber Tech Inc.Discussions and field cooperation from all the Engineering and maintenance staff of USACE at their headquarters and various locations are sincerely acknowledged.
Slide31Questions?
Thank you!