Engineering Commons^™

Inspection Training Course On Bridge Preventive Maintenance Activities, Danny Wells, Sudhir Palle

Kentucky Transportation Center Research Report

Despite over 30 percent of bridges in the United States having exceeded their 50-year design lives, most state departments of transportation (DOTs) lack the funding needed to replace bridges on a large scale. In response, agencies have increasingly turned to bridge preventive maintenance activities to prolong bridge service lives. These activities provide a safe and cost-effective way to slow the rate at which structures deteriorate, mitigate the effects of aging, and improve bridge functional condition. The Kentucky Transportation Cabinet (KYTC) has become increasingly reliant on preventive maintenance to preserve and extend the service lives of its steel and concrete bridges. …

Steel Bridge Coating Inventory For 2022, Christopher Goff, Sudhir Palle

Kentucky Transportation Center Research Report

The Kentucky Transportation Cabinet (KYTC) has replaced the lead-based coatings on many of its steel bridges over the past 30 years. In the 1980s and 1990s, inorganic zinc primers with vinyl topcoats were the go-to option for coating replacement projects. Since 2000, the typical choice for these projects has been organic zinc primers that are part of a two- or three-coat system. Some of these coatings have localized failures in high-stress areas. KYTC’s current inventory of steel bridges numbers over 1,100 structures. Accounting for expected service lives, to properly maintain protective coatings on these bridges will require the Cabinet to …

Assessment Of Deteriorated Structural Concrete To Provide Durable Repairs, Theodore Hopwood, Christopher Goff, Sudhir Palle

Kentucky Transportation Center Research Report

Most of the structural elements on Kentucky bridges are made of reinforced concrete. Many of these elements deteriorate as a result of corrosion of the reinforcing steel caused by carbonation and — primarily — applications of chlorides by the Kentucky Transportation Cabinet (KYTC). Corrosion of reinforcing steel is reviewed along with assessment procedures that leverage nondestructive evaluation (NDE) methods and related laboratory and field tests. Several maintenance procedures are discussed, including the application of sealers and coatings, patch and major concrete repairs, and electrochemical methods. Incorporating NDE and test results into maintenance procedure selection is discussed. Recommendations are provided on …

Determination Of Steels In Kentucky Bridges, Theodore Hopwood Ii, Christopher Goff, Sudhir Palle

Kentucky Transportation Center Research Report

The Kentucky Transportation Cabinet (KYTC) maintains over two hundred steel bridges constructed with types of steel which are unknown. Kentucky Transportation Center (KTC) researchers have developed a procedure for determining steel tensile properties (0.2% yield strength and ultimate tensile strength) which can be used to help identify unknown steels. The procedure involves extracting small coupons from the lower flanges of steel deck girder bridges. Coupons are then machined into sub-sized tensile testing specimens and suitable shapes for chemical analyses. Sub-sized tensile tests returned values generally comparable to those provided in mill certifications of steels purchased for laboratory trials. Several analytical …

Identification Of Bridges With Fracture-Prone Details, Theodore Hopwood Ii, Rick Younce, Sudhir Palle

Kentucky Transportation Center Research Report

Welded steel girder bridges can contain details that can high welding and service stresses and are termed constraintinduced fractures (CIF). The Kentucky Transportation Cabinet has steel bridges with weld details known to cause CIFs whose girders have experienced fracture events. The Cabinet’s bridge inventory was reviewed and additional candidate bridges with potential CIF details were identified. A review of bridge plans and pictures along with followup field investigations pinpointed bridges with CIF details that warrant up-close (i.e., arm’s length) inspections. Several uninspected bridges were identified as candidates for inspection to determine if they contain CIF details. Guidance is provided to …

Improved Bridge Joint Materials And Design Details, Theodore Hopwood Ii, Christopher W. Van Dyke, Sudhir Palle

Kentucky Transportation Center Research Report

Expansion joints accommodate bridge movements that result from factors such as thermal expansion and contraction, concrete shrinkage, creep effects, live loading, settlement of the foundation and substructure, and environmental stressors. Expansion joints fall into two categories — open joints and closed joints. Open joints contain gaps that facilitate the passage of water and debris runoff through bridge joints. Flexible or stiff troughs are generally installed beneath open joints to direct runoff away from bridge elements. Closed joints produce a watertight seal that inhibits water, debris, and deicing materials from passing through bridge joints and remaining in contact with underlying bridge …

Bridge End Settlement Evaluation And Prediction, Jiwen Zhang, Timothy R. Taylor, Roy E. Sturgill

Kentucky Transportation Center Research Report

A bridge approach is usually built to provide a smooth and safe transition for vehicles from the roadway pavement to the bridge structure. However, differential settlement between the roadway pavement that rests on embankment fill and the bridge abutment built on more rigid foundation often creates a bump in the roadway. Previous work examined this issue at a microscopic level and presented new methods for eliminating or minimizing the effects at specific locations.

This research studies the problem at a macroscopic level by determining methods to predict settlement severity; this assists designers in developing remediation plans during project development to …

Evaluation Of The Use Of Painted And Unpainted Weathering Steel On Bridges, Theodore Hopwood Ii, Sudhir Palle, Bobby W. Meade, Rick Younce

Kentucky Transportation Center Research Report

KTC researchers studied the use of unpainted weathering steel on bridges, using findings of inspections performed on Kentucky Transportation Cabinet (KYTC) bridges constructed with both painted and unpainted weathering steel as well as laboratory testing. Laboratory tests were conducted on test panels of conventional and weathering grades of steel to determine the performance of barrier and zinc-based coatings over abrasive-blasted substrates of those steel types in both the new and corroded conditions. The report provides the following recommendations for the use of painted and unpainted weathering steel on Kentucky bridges based upon both the field and laboratory findings:

• KYTC should …

Evaluation Of Deterioration Of Structural Concrete Due To Chloride Intrusion And Other Damaging Mechanisms, Sudhir Palle, Brian K. Howell, Theodore Hopwood Ii, Bobby W. Meade

Kentucky Transportation Center Research Report

Kentucky's bridges continue to age and experience distress. The intrusion of chlorides into concrete remains the primary mechanism for deterioration. It leads to reinforcing steel corrosion that damages the adjoining concrete structure. This study found problematic chloride concentrations in Kentucky concrete bridge elements (decks, pier caps, abutments). Chloride levels have been found at concentrations sufficient to initiate reinforcing steel corrosion. In some cases, chloride concentrations were sufficient to cause accelerated corrosion and produce major section loss of reinforcing steel. Advanced stages of corrosion such as these typically require costly repairs and maintenance to extend the service life of bridges.

Field …

Preventive Maintenance Program For Bridges, Theodore Hopwood Ii, Jared Fairchild, Bobby W. Meade, Sudhir Palle

Kentucky Transportation Center Research Report

The Kentucky Transportation Cabinet’s (KYTC) bridge inventory is rapidly aging. As such, the Cabinet needs to identify and implement relevant preventative maintenance (PM) actions to extend the useful service lives of those structures. Maintenance actions, costs, and application interval/repair durability information have been obtained for both cyclical and condition - based bridge PM. Additionally, information rehabilitation actions were acquired from a regional DOT survey and from other literature. As part of this study, the Kentucky Transportation Center (KTC) researchers monitored a KYTC bridge washing project to assess its level of effectiveness and to identify potential improvements. Based upon these tasks, …

Sealants, Treatments And Deicing Salt Practices To Limit Bridge Deck Corrosion And Experimental Deck Sealants And Pier Cap Coating On Interstate 471, Danny Wells, Sudhir Palle, Bobby W. Meade, Theodore Hopwood Ii

Kentucky Transportation Center Research Report

This project evaluated the ability of concrete sealants to impede the ingress of chloride ions into concrete bridge decks. Laboratory testing evaluated 24 concrete-penetrating sealants and four film-forming products. The products were selected based on survey results from adjacent state transportation agencies. KTC assisted the KYTC in developing Special Notes for applying four experimental sealants to two bridges (B00056L & B00056R) located on Interstate 471, over 6th Street in New Port, Kentucky. The sealants chosen for the field-testing were intended to reduce the ingress of chloride ions when deicing materials are applied to road surfaces. Pre- and post-application friction test …

New Coatings For Bridges (Over-Coat Systems), Sudhir Palle, Theodore Hopwood Ii, Bobby W. Meade

Kentucky Transportation Center Research Report

KYTC sought to identify new coatings technologies consistent with overcoating that offer enhancements in terms of ease of application and performance. KYTC contacted paint manufacturers to obtain sample coating systems for characterization by the KYTC Division of Materials and accelerated performance testing by Kentucky Transportation Center (KTC). A total of 14 coating systems from five manufacturers underwent performance testing according to ASTM D5894.

Fluorescing Coatings For Improved Inspection During Bridge Maintenance Painting, Bobby W. Meade, Theodore Hopwood Ii, Sudhir Palle

Kentucky Transportation Center Research Report

Optically active pigments (OAPs) fluoresce under light exposures with wavelengths (nm) producing emissions in the visible spectra (380 to 740 nm). They are used as paint pigments to aid visual inspection of applied coatings for defects such as pin-holing and incomplete coverage. OAP coatings are widely used in various industries outside of bridge maintenance painting.

This study addressed the laboratory evaluation and field trial of an OAP coating for KYTC bridges. OAP coatings were evaluated for inspectability and accelerated weathering performance in a laboratory test program. After successful laboratory performance, OAP coatings were specified for a KYTC bridge painting project …

Improved Bridge Expansion Joints, Sudhir Palle, Theodore Hopwood Ii, Bobby W. Meade

Kentucky Transportation Center Research Report

The Kentucky Transportation Cabinet (KYTC) has both open and closed bridge expansion joints and associated details that are problematic. Several state highway agencies (SHA) have joints that they believe are superior performers to other types and have prepared guidance documents for their use. A literature search indicated that several previous research studies, including national surveys, addressing SHA joint practices have been conducted over the past 10 years. For up-to-date information, a new set of surveys were developed and distributed to all the SHAs by email through the AASHTO Subcommittee on Maintenance-Bridge Technical Working Group chairman in June 2010. There were …

Automated Chemical Stabilizing Of Leaded Paint Residue From Bridge Maintenance Painting Operations, Bobby W. Meade, Theodore Hopwood Ii, Sudhir Palle

Kentucky Transportation Center Research Report

This study addressed the use of automated equipment to dose and mix lead stabilizing compounds to allow leaded paint residue/debris to be disposed at in-state contained landfills. The stabilizing would be conducted in situ at bridges being subjected to maintenance painting operations involving total coating removal and replacement. Many Kentucky bridges have existing painting that contains lead compounds at levels which may constitute hazardous wastes upon removal. The KYTC practice of recycling lead containing residue is working well at this time but the issue of a single recycler available continues to place KYTC in a position of returning to hazardous …

Kentucky Bridges With High-Strength Quenched And Tempered Steel, Theodore Hopwood Ii, Jared Fairchild

Kentucky Transportation Center Research Report

The Kentucky Transportation Cabinet (KYTC) has several bridges employing high-strength quenched and tempered (QT) steels. In the past several decades, weld and corrosion cracking problems have occurred with QT steel in three KYTC bridges. This material has typically been employed on large bridges in fracture-critical members which increases the concern about these steels. This study was performed to review the KYTC steel bridge inventory and identify bridges/structural member containing QT steels. The list consisted of any KYTC maintained bridge with an individual span greater than 150 feet. KTC used this list to identify each bridge and members containing QT steel. …

Nondestructive Testing Of Defective Astm A 514 Steel On The I ‐ 275 Combs‐Hehl Twin Bridges Over The Ohio River In Campbell County, Kentucky, Theodore Hopwood Ii, Sudhir Palle

Kentucky Transportation Center Research Report

Three defective ASTM A 514 steel splice plates were discovered on the I-275 Combs-Hehl twin bridges over the Ohio River. A follow-on in-depth field inspection of 1,356 A 514 steel plates on the bridges revealed 14 additional defective gusset and splice plates. The A 514 steel was improperly heat-treated resulting in a brittle crack-prone microstructure. Ultrasonic and impact hardness tests were used to identify the defective steel. Subsequently, the defective steel plates were either removed or lapped with additional steel plates.

Experimental Painting Of The I-64 Riverside Parkway In Louisville, Ky, Rick Younce, Theodore Hopwood Ii, Sudhir Palle

Kentucky Transportation Center Research Report

The Kentucky Transportation Cabinet conducted a large-scale zone maintenance painting operation on 13 elevated steel bridges along the I-64 Riverside Parkway in Louisville, KY in 2007. That work included abrasive blast-cleaning and painting of steel underlying open deck joints on 3.2 miles of steel structures. The painting was performed by spray application of one coat of a calcium sulfonate alkyd coating. The painting covered an area of 237,060 ft2 of steel cleaned and painted at a unit cost of $15.82/ft2.

The project incorporated a high level of containment as the existing coating possessed lead-based paints and the project was located …

Site Investigation Of Bridges On And Over The Parkways In Western Kentucky, Jindong Hu, Tong Zhao, Issam E. Harik, Jian Xie

Kentucky Transportation Center Research Report

Determination of the seismic risk of the bridges on and over the parkways in Western Kentucky requires evaluating the current condition of the individual elements of the bridges. Except for culverts, all bridges were visually inspected, photographed and the records were stored in a database. Data of the visual inspection and the photographs were combined to form the completed site inspection forms. Any visually observed deficiencies of the bridge elements were recorded.

A Compact Disc (CD) that includes pictures of the bridges is attached to this report. The site inspection forms of all bridges on and over the parkways in …

Preliminary Seismic Evaluation And Ranking Of Bridges On And Over The Parkways In Western Kentucky, Jian Xie, Issam E. Harik, Tong Zhao, Jindong Hu

Kentucky Transportation Center Research Report

Five parkways in Western Kentucky are located in the region that is greatly influenced by the New Madrid and Wabash Valley Seismic Zones. This report executes a preliminary screening process, known also as the Seismic Rating System, for bridges on and over parkways in Western Kentucky to identify the seismic vulnerable bridges.

The ranking of bridges derived from this rating system is based on: structural vulnerability, seismic and geotechnical hazards, and bridge importance. There are 349 bridges were ranked with the Seismic Inventory of Bridges (SIB), a user-oriented database program developed according to the Seismic Retrofitting Manual. The bridge ranks …

Prevention Of Voc Releases From Bridge Painting Operations, Theodore Hopwood Ii, Rick Younce, Sudhir Palle

Kentucky Transportation Center Research Report

Bridge maintenance painting employs solvent-based coatings that generate volatile organic compounds (VOCs) that contribute to air-quality problems. Methods for capturing VOCs during normal Kentucky Transportation Cabinet (KYTC) maintenance painting operations were investigated. One method, activated carbon adsorption, is adaptable to KYTC operations. Related factors including area of bridge, coating systems, containment volumes and VOC out gassing rates were reviewed. A commercial source of activated carbon adsorption equipment was identified and issues related to employing that technology for bridge painting were identified.

Preliminary Seismic Evaluation And Ranking Of Bridges Along I-24 In Western Kentucky, Wael Zatar, Issam E. Harik, Peng Yuan, Ching Chiaw Choo

Kentucky Transportation Center Research Report

This study represents one of the Seismic Evaluation of I-24 Bridges investigative series. The focus is on preliminary seismic evaluation and ranking of bridges according to their seismic vulnerability. Bridges along I-24 are considered in this investigation. The ranking will assist in identifying and prioritizing bridges for secondary evaluation, retrofit measure, or other course of action. The rating system described herein is based on a methodology provided by the FHWA Retrofitting Manual for highway bridges. One hundred and twenty seven (127) highway bridges were evaluated and rated in this process for projected 50-year and 250-year seismic events. The Tennessee River …

Seismic Evaluation Of I-24 Bridges And Embankments In Western Kentucky–Summary Report, Wael A. Zatar, Issam E. Harik, Ching Chiaw Choo

Kentucky Transportation Center Research Report

I-24 is considered as one of the high priority and emergency routes in the region. Hence, it is essential that I-24 remains functional and operational after an earthquake event. The objective of this study is to perform seismic evaluation and risk assessment of bridges and embankments along I-24 in western Kentucky. The assessment assists identifying and prioritizing bridges that are susceptible to failure.

The study aims at evaluating the seismic risk for 127 bridges, of which 82 bridges lies on I-24 and 45 bridges cross over I-24. This report is the first (1st) in a series of seven reports for …

Seismic Evaluation Of The Cumberland River Bridges On I-24 In Western Kentucky, Wael A. Zatar, Wei-Xin Ren, Issam E. Harik

Kentucky Transportation Center Research Report

The main objective of this study is to assess the structural integrity of the I-24 parallel bridges at the Cumberland River crossing in western Kentucky. Due to its importance, the bridge is evaluated for the 250-year event and the maximum credible 500-year event. The scope of the work included: 1) Field testing of the main bridge; 2) Finite element modeling and calibration; 3) Time-history seismic response analysis for the main spans; and 4) Seismic evaluation for both the main and the approach spans. The seismic analysis for the 250-year event indicates that the main spans of the bridge can resist …

Site Investigation Of Bridges Along I-24 In Western Kentucky, Wael Zatar, Issam E. Harik, Peng Yuan

Kentucky Transportation Center Research Report

Determination of the seismic risk of the I-24 bridges requires evaluating the current condition of all individual elements of the bridges. All bridges along the I-24 were visually inspected, pictured, and the records were stored in a database. Data of the visual inspection and the pictures were combined to form the completed site inspection forms of the I-24 bridges. Main visually observed deficiencies of the bridge elements were pointed out. The site inspection forms of all bridges on/over the I-24 in western Kentucky are used together with the bridge inventory to obtain different statistical figures regarding the characteristics of the …

Seismic Evaluation And Ranking Of Bridge Embankments Along I-24 In Western Kentucky, Wael Zatar, Issam E. Harik, Peng Yuan, Ching Chiaw Choo

Kentucky Transportation Center Research Report

This study represents one of the Seismic Evaluation of I-24 Bridges investigative series. The focus is on slope or embankment stability and liquefaction potential of embankments of bridges along I-24 in Western Kentucky. A rating system is derived to assist in identifying and prioritizing bridge embankments that are susceptible to failure during to projected seismic events. Embankments of one hundred and twenty seven (127) bridges along I-24 in Western Kentucky are evaluated for 50-year and 250-year seismic events. Fifty-two (52) of the 127 embankments were rated as ‘critical’ for the 50-year event, and 60 were rated as ‘critical’ for the …

Coatings, Sealants, And Fillers To Address Bridge Concrete Deterioration And Aesthetics-Phase 1, Sudhir Palle, Theodore Hopwood Ii

Kentucky Transportation Center Research Report

This study addresses experimental evaluation and testing of concrete coatings for maintenance purposes on structural (steel reinforced) concrete. The test methods employed are intended to identify coatings and sealers for eventual incorporation into a qualified products list for structural concrete coatings. Some of the methods/procedures used in this study will be used in the future to evaluate additional coatings and sealers. Developmental work focused on identifying relevant coatings systems and laboratory tests. The objectives of experimental project monitoring were to: 1) identify existing viable concrete coatings along with their properties/ characteristics/surface preparation requirements and determine effective acceptance/evaluation tests for those …

Disposal Of Bridge Paint Residue, Theodore Hopwood Ii, Sudhir Palle

Kentucky Transportation Center Research Report

Paint residue generated by bridge maintenance painting commonly contains lead requiring the residue to be disposed of as a hazardous waste. Several alternatives are being investigated in this study, chemical stabilization and recycling as options for the Kentucky Transportation Cabinet (KYTC) to consider in addressing the waste stream generated by bridge maintenance painting operations.

In the initial portion of this study, four chemical stabilization materials were identified as candidates for xperimental/demonstration projects entailing maintenance painting. A recycling option was also provided. An experimental bridge painting project was let by KYTC to investigate the use of two chemical stabilizers and the …

Evaluation Of The Service Performance Of Bridge Components, Theodore Hopwood Ii, Robert Brown

Kentucky Transportation Center Research Report

This study was initiated to provide review of common bridges to determine the performance of their components. Seven bridge types were selected that constituted 85 % of the Kentucky Transportation Cabinet (KYTC) bridge inventory. 319 bridges were inspected by Kentucky Transportation Cabinet (KTC) researchers, representing 5 about % of those bridges. Common details/components were identified and evaluated including features of interest to the KYTC Study Advisory Committee. In addition to those findings, KTC researchers evaluated KYTC National Bridge Inventory reports and maintenance needs forms for the same bridges.

Design modifications/material changes were recommended to improve performance of new bridges. Additionally, …

Survey Of Welding Processes, Theodore Hopwood Ii

Kentucky Transportation Center Research Report

The current KYTC “SPECIAL PROVISION NO. 4 WELDING STEEL BRIDGES” prohibits the use of welding processes other than shielded metal arc welding (SMAW) and submerged arc welding (SAW). Nationally, bridge welding is codified under ANSI/AASHTO/AWS D1.5M/D1.5:2002 Bridge Welding Code. That document allows the use of other welding processes including flux core arc welding, gas metal arc welding, electroslag welding and electrogas welding after passing qualification tests.

Both the KYTC Special Provision and the Bridge Welding Code were reviewed. Representatives from 14 state highway agencies, fabrication shops, universities and welding equipment firms were questioned regarding the wider use of the welding …