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![Page 1: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/1.jpg)
Bridge Engineering
Research Turner-Fairbank Highway Research Center
FHWA BRIDGE ENGINEERING RESEARCH
Ben Graybeal, Ph.D., P.E., FHWA, [email protected], (202)493-3122
Other Contacts for Presented Topics:
Justin Ocel, Ph.D., P.E., FHWA, [email protected], (202)493-3080
Terry Arnold, FHWA, [email protected], (202)493-3305
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Bridge Engineering
Research Turner-Fairbank Highway Research Center
STRUCTURAL CONCRETE RESEARCHBen Graybeal, Ph.D., P.E., FHWA, [email protected], (202)493-3122
STRUCTURAL STEEL RESEARCHJustin Ocel, Ph.D., P.E., FHWA, [email protected], (202)493-3080
STRUCTURAL MATERIALS RESEARCHTerry Arnold, FHWA, [email protected], (202)493-3305
![Page 3: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/3.jpg)
Bridge Engineering
Research Turner-Fairbank Highway Research Center
ULTRAGIRDERBen Graybeal, Ph.D., P.E., FHWA, [email protected], (202)493-3122
HOMOPOLAR GENERATOR WELDINGJustin Ocel, Ph.D., P.E., FHWA, [email protected], (202)493-3080
ALKALI-SILICA REACTION TESTTerry Arnold, FHWA, [email protected], (202)493-3305
![Page 4: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/4.jpg)
Bridge Engineering
Research Turner-Fairbank Highway Research Center
ULTRAGIRDERBen Graybeal, Ph.D., P.E., FHWA, [email protected], (202)493-3122
Marrying UHPC, 0.7” strands, and refined
cross sections to deliver the future of
pretensioned girders
![Page 5: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/5.jpg)
ULTRAGIRDER Concept
F.I.B.-102, Concrete Girder
(66) 0.6-in. strands
FIB 102
0.6" Strands
4'-1"
3'-3"
8"
8'-6"
FIB 102
0.7" Strands
4'-1"
3'-3"
8"
8'-6"
FIB 102 - 6" Web
0.7" Strands
4'-1"
3'-3"
6"
8'-6"
FIB 120 - 6" Web
0.7" Strands
3'-3"
3'-9"
6"
10'
Conventional
concrete
FIB 102
0.6" Strands
4'-1"
3'-3"
8"
8'-6"
FIB 102
0.7" Strands
4'-1"
3'-3"
8"
8'-6"
FIB 102 - 6" Web
0.7" Strands
4'-1"
3'-3"
6"
8'-6"
FIB 120 - 6" Web
0.7" Strands
3'-3"
3'-9"
6"
10' UHPC
Conventional
concrete
(92) 0.7-in. strands
Span =
300 ft
Span =
200 ft
UltraGirder
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UltraGirder Project Experimental Program
Precast Plant 1 in New Jersey using UHPC A
Precast Plant 2 in Florida using UHPC B
Modified
PCEF-39 and
PCEF-47sections
• Girders reinforced with 0.7 in. diameter strands
prestressed to 59.5 kips
• Total prestressing force in section up to 1,547 kips
UltraGirder
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Girder Reinforcement
UltraGirder
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UltraGirder
![Page 9: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/9.jpg)
UltraGirder
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UltraGirder
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Engineering New Solutions…
UltraGirder concepts can facilitate:
• Longer Spans
• Shallower Girders
• Lighter Girders
• Reduced End Zone Concerns
• More Durable Solutions
• Increased Competition11
UltraGirder
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Interested in the innovation?
FHWA/TFHRC welcomes partners who want to
work with us to bring these innovations into
practice.
ULTRAGIRDERBen Graybeal, Ph.D., P.E., FHWA,
[email protected], (202)493-3122
12
UltraGirder
![Page 13: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/13.jpg)
Bridge Engineering
Research Turner-Fairbank Highway Research Center
HOMOPOLAR GENERATOR WELDINGJustin Ocel, Ph.D., P.E., FHWA, [email protected], (202)493-3080
A Novel Advancement in
Steel Joining Technology
![Page 14: FHWA BRIDGE ENGINEERING RESEARCH · Bridge Engineering Research Turner-Fairbank Highway Research Center STRUCTURAL CONCRETE RESEARCH Ben Graybeal, Ph.D., P.E., FHWA, benjamin.graybeal@dot.gov,](https://reader030.vdocuments.net/reader030/viewer/2022040109/5e79f89c8b44d00f460b028c/html5/thumbnails/14.jpg)
Homopolar Generator Welding
Why?
• How long to completely weld a 3” thick, 30” wide steel
plate with conventional submerged arc welding?
14
• What if you could do it in fractions of a second?
~ 30 hours
Homopolar Generator Welding
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How does it work?
15
** Images copyrighted KAI, LLC. **
… Convert Kinetic Energy into Electric Current …
Homopolar Generator Welding
Current vs. Time
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16
** Image copyrighted KAI, LLC. **
How does it work?
¼ scale HPG and
forging fixture built
for SBIR.
Starting with
6 x 1 inch welds
Homopolar Generator Welding
HPGW = resistance heating + forging
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The real deal…
17
** Video copyrighted KAI, LLC. **
Homopolar Generator Welding
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FHWA Evaluation of HPG Welds
• ASTM A709 HPS 70W plate
• Evaluating reduced section tension,
side bends, and CVN energy
• Evaluated two welds so far
18
Homopolar Generator Welding
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HPG Weld Testing: Reduced Section Tension
19
Fusion Line
Fusion Line
0
20
40
60
80
100
120
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
Engin
eeri
ng S
tres
s (k
si)
Engineering Strain
Measured Base Metal Tensile
AASHTO/AWS D1.5 Requirement PASS!
Fractured in base metal,
strength exceeds
AASHTO/AWS D1.5
requirement
Homopolar Generator Welding
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HPG Weld Testing: Side Bend Tests
20
PASS!
No Defects
Homopolar Generator Welding
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HPG Weld Testing: Charpy V-Notch
21
A work in
progress…
0
50
100
150
200
250
300
-120 -100 -80 -60 -40 -20 0 20 40 60 80 100
Imp
act E
nerg
y (l
bf-
ft)
Temperature ( F)
Base metal L-T direction resultsASTM A709 HPS 70W requirements
are 25 ft-lbf @-10 F for non-fracture
critical members or 35 ft-lbf @-10 F
for fracture critical members
Weld results (green squares)AASHTO/AWS D1.5 requires
25 ft-lbf@-10 F for temperature
zones I and II
Homopolar Generator Welding
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HPG Weld Testing: Charpy V-Notch
22
Hypothesis: the forging pressure is too low
Broken CVN left side (50x) Broken CVN right side (50x)V-notch
Porosity or
inclusions
Homopolar Generator Welding
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Next Steps…
Process optimization still on-going
Low impact resistance can likely be mitigated
Maybe more to report next year
23
Homopolar Generator Welding
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Interested in the innovation?
FHWA/TFHRC welcomes partners who want to
work with us to bring these innovations into
practice.
HOMOPOLAR GENERATOR WELDJustin Ocel, Ph.D., P.E., FHWA,
[email protected], (202)493-3080
24
Homopolar Generator Welding
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Bridge Engineering
Research Turner-Fairbank Highway Research Center
ALKALI-SILICA REACTION TESTTerry Arnold, FHWA, [email protected], (202)493-3305
A Better, Quicker and More Reliable
Method to Assess ASR Susceptibility
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Current ASR Tests Originate from 1948
• Meilenz, Green and Benton (ACI 1947)
• Sprague, Hun et al. (ACI 1948)
• 1-N Sodium Hydroxide 800C
• Measured Mortar Bar Expansion
ASR Aggregate Testing
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ASTM C 289 - poor reliability
Petrography - useful tool but depends on skill
ASTM C 227 - leaching
ASTM C 1260 - overly severe
ASTM C 1293 - long testing period, leaching,
unsuitable for the eval. of job mix
Aggregates
Mortar
Concrete
Current ASR Tests Methods
ASR Aggregate Testing
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FHWA/TFHRC ASR Aggregate Test – Pure Chemistry
• Mill Report
• Mix Design
• 5g Aggregate
• 21 Days
ASR Aggregate Testing
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FHWA/TFHRC Chemistry Lab (2009-2019)
• Studied Chemistry of ASR Gels
• ASR gel has no unique composition
• Chemical composition of gels affect structure
which affects expansion
• Raman Spectroscopy helped identify what
chemical parameters are important in a test
ASR Aggregate Testing
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ASR
TESTS
Aggressive
Environment Possibility
to test job
mix
Realistic
concrete
pore
solution
Testing
period
Mirror
field
performance
Testing
EfficiencyAlkali
conc.Temp.
ASTM
1260Yes Yes No No
14
daysNo Medium
ASTM
1293Yes No No No 1 year Mostly Low
TFHRC
Chemical
TestNo No Yes Yes
21
daysYes High
Comparison of Accelerated ASR Tests
ASR Aggregate Testing
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Expansion
No ExpansionFalse Positive
False Negative
ASR Aggregate Testing
Correlation with Physical Expansion (TFHRC Test)
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o The test can accurately detect highly and non reactive coarse
aggregates
o Intermediate reactive aggregates are more challenging
o Comparison of lab test results with known field block expansion
shows good correlation.
o We are looking for field cases and block farm data to further populate
the calibration charts.
TFHRC Rapid Chemical ASR Test
ASR Aggregate Testing
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Calibration of TFHRC ASR Test
Field Cases, block farms, or structures
• Aggregate samples 500g.
• Cement samples 50g or mill certificate
• Mix Design
• Expansion Data (New and Historical)
ASR Aggregate Testing
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Interested in the innovation?
FHWA/TFHRC welcomes partners who want to
work with us to bring these innovations into
practice.
ASR TEST METHODTerry Arnold, FHWA,
[email protected], (202)493-3305
37
ASR Aggregate Testing
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Bridge Engineering
Research Turner-Fairbank Highway Research Center
ULTRAGIRDERBen Graybeal, Ph.D., P.E., FHWA, [email protected], (202)493-3122
HOMOPOLAR GENERATOR WELDINGJustin Ocel, Ph.D., P.E., FHWA, [email protected], (202)493-3080
ALKALI-SILICA REACTION TESTTerry Arnold, FHWA, [email protected], (202)493-3305