hillman composite beams - etouches...overall cost favored replacement with hcb span! university of...
TRANSCRIPT
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John Hillman, PE, SE
Brisbane, Australia
November 28, 2017
HILLMAN COMPOSITE BEAMS
8th Australian Small Bridges Conference
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HCB
A structural member
using several different
building materials
resulting in a cost
effective composite
beam designed to be
stronger, lighter and
more corrosion
resistant
Compression Reinforcing
Tension Reinforcement
FRP Shell
Shear Connectors
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• Balanced quad-
weave fabric with
fibers that are
horizontal (00),
vertical (900) and
(± 450)
• infused in an
epoxy vinyl ester
resin matrix
Fiberglass Box (FRP Shell)
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• Tension reinforcing
consisting of 1,860 MPa
(270 ksi) galvanized
prestressing strand
along bottom of beam
Tension Reinforcing
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Work Cell - VARTM Fabrication
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Staging Area and Top Flange Cell
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• Compression
reinforcing
consisting of
41MPa (6,000 psi)
Self-Consolidating
Concrete (SCC)
pumped into
internal arch-
shaped conduit
Compression Reinforcing - SCC
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• Lighter Weight (reduces foundations)
• Reduced Carbon Footprint
• Optimization of every material used
• Sustainable (greater corrosion resistance)
• Simplicity in Design, Fabrication and Erection
• “SAFER” bridges through better performance
Benefits of HCB Technology
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The Benefits of HCB
• Reduce the burden of infrastructure maintenance
on future generations through better performance.
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From Concept - 1996
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Stress History
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Tension Field Action - (TFA)
Experimental vs. ABAQUS (no bracing)
Images courtesy of Virginia Tech
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Shear Capacity Analysis
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Strain Compatibility - Force Equilibrium
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Solving for Neutral Axis
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C=T
C=0.85fc’ab
ΦMn=ΦC(d-a/2)
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• Inventory Rating = 2.68 (HS-54)
• Operating Rating = 3.47 (HS-69)
Laboratory Testing - 2009
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1st HCB Installation - TTCI - Pueblo, CO
9.1m (30 ft.) - Class 1 RR (320k), Nov. 2007
To Reality - 2007
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High Road Bridge - Lockport Township, IL
18m (57 ft.) Span - August, 2008
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Route 23 Bridge, Cedar Grove, NJ
9.4m (31 ft.) Span - October 2009
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Knickerbocker Bridge - Boothbay, ME
165m (540 ft.) - 8 spans @ 21.3m (70 ft) - Oct. 2010
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B0439 - Route 76 over Beaver Creek, MO (3-span)55m (180 ft.) w/838mm (33 in) HCB - Nov 2011
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B0410 - Lockwood, MO - July 2012
32.3m (106 ft.) span w/1524mm (60 in) HCB
Double Box
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Tides Mill - Colonial Beach, VA - Feb 2013
13.5m (44 ft.) span 45 deg Skew 21 in. HCB
USE TESTINGPHOTO
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Union Street - Bangor, ME - Nov 2014
27.4m (90 ft.) span w/1067mm (42 in) HCB
Double Box
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42 ft. HCB Span B. 218.83 - Boise City Sub , CO
Revenue Service at Last
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1st HCB Railroad Revenue Service - Fernie, BC
10m (33 ft.) - Canadian Pacific Railway, Oct. 2014
CP Railway concluded that constructibility and overall cost favored replacement with HCB span!
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University of Maine Research Pier, Machias, ME
30.5m (100 ft.) 3-span w/18 in. HCB - Sep 2011
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HCB combined w/ FRP stay-in-place form
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First HCB Bridge in Australia!
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Wyndham Ridge Bridge 2, Greta NSW, Australia
15.0m (49 ft.) 3-span w/615mm HCB - Nov 2017
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Big Crane vs. Little Crane
• 838mm Precast Box Beam• 1,168 kg/m
• 21.3 m = 24.9 tonnes
• 1 Beam/truck
• 838mm HCB• 115 kg/m – empty
• 21.3 m = 2.4 tonnes
• 6 Beams/truck
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Dollies vs. Travel Lifts
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• How do I know if the HCB is properly filled?
• What if the strands are damaged?
• What happens if a truck hits the bridge?
• How do I repair an HCB bridge?
I know the HCB works, but...
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Basic HCB Bridge construction process.
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The Show-Me-State believes us!
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• Damaged HCB w/12 of 22 strands cut
• Residual Capacity - 83,000 lbs
Don’t worry about damaged strands!
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4.5 Ton concrete mass accelerated to produce no less
than 100 kJoules of energy at impact
We know trucks hit bridges.
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No HCBs were harmed in the making of this video!
We apologize for any damage to your truck.
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Any damage to HCB was cosmetic
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Same impact force on precast concrete beam
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HCB bridges easy to repair!
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What do these 3 objects have in common?
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They don’t build raquets like they used to!
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They don’t build boats like
they used to either!
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Acknowledgements
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The “Traditional” Least Cost Alternate
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www.hcbridge.com
When it comes to Safety...Performance is more important than tradition!
They don’t build them like they used to.
Neither do we!!!