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Final ReportFHWA/IN/JTRP – 2004/4Evaluation and Repair of Wrought Iron and SteelStructures in IndianabyMark D. BowmanProfessor of Civil EngineeringandAmy M. PiskorowskiGraduate Research AssistantSchool of Civil EngineeringPurdue UniversityJoint Transportation Research ProgramProject No: C-36-SGJJJFile No: 7-4-61SPR-2655Conducted in Cooperation with theIndiana Department of TransportationAnd the U.S. Department of TransportationFederal Highway AdministrationThe contents of this report reflect the views of the authors who are responsible for thefacts and accuracy of the data presented herein. The contents do not necessarily reflectthe official view or policies of the Federal Highway Administration or the IndianaDepartment of Transportation. This report does not constitute a standard, specification,or regulation.Purdue UniversityWest Lafayette, IndianaJune 2004
1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.FHWA/IN/JTRP-2004/4TECHNICAL REPORT STANDARD TITLE PAGE4. Title and SubtitleEvaluation and Repair of Wrought Iron and Steel Structures in Indiana5. Report DateJune 20046. Performing Organization Code7. Author(s)Mark D. Bowman, Amy M. Piskorowski9. Performing Organization Name and AddressJoint Transportation Research Program1284 Civil Engineering BuildingPurdue UniversityWest Lafayette, IN 47907-12848. Performing Organization Report No.FHWA/IN/JTRP-2004/410. Work Unit No.11. Contract or Grant No.SPR-265512. Sponsoring Agency Name and AddressIndiana Department of TransportationState Office Building100 North Senate AvenueIndianapolis, IN 4620413. Type of Report and Period CoveredFinal Report14. Sponsoring Agency Code15. Supplementary NotesPrepared in cooperation with the Indiana Department of Transportation and Federal Highway Administration.16. AbstractThroughout the state of Indiana, there a number of older, historical bridges which have been in service since the late 19 thcentury. Many, although not all, of these bridges are truss structures comprised either partially or completely of wrought ironmembers. Moreover, most of them need some degree pf maintenance or rehabilitation. However, engineers who mustrecommend repair or rehab operations typically do not know the material properties and behavior of wrought iron members.Consequently, an investigation was initiated to review and classify typical material properties of wrought iron members. Thisinvestigation involved three phases that included a literature review of other research and bridge rehabilitation studies, asurvey of many transportation agencies throughout Indiana and the United States, and fundamental material and mechanicaltesting in the laboratory. Based upon this research, rehabilitation and repair recommendations for wrought iron members inexisting bridges were then developed..17. Key Wordshistoric bridges, bridge rehabilitation, wrought iron, trussbridges, repair procedures, rehabilitation, welding.18. Distribution StatementNo restrictions. This document is available to the public through theNational Technical Information Service, Springfield, VA 2216119. Security Classif. (of this report)20. Security Classif. (of this page)21. No. of Pages22. PriceUnclassifiedUnclassified242Form DOT F 1700.7 (8-69)
Page 1: Purdue UniversityPurdue e-PubsJTRP
Page 6 and 7: epairing a bent wrought iron tensio
Page 8 and 9: vPageCHAPTER 3TEST PROCEDURES FOR M
Page 10 and 11: ixLIST OF FIGURESFigurePageFigure 1
Page 12 and 13: xiFigurePageFigure 3.30 Top View of
Page 14 and 15: xiiiFigurePageFigure 5.12 Typical T
Page 16 and 17: xvAppendix FigurePageFigure D.7 Ini
Page 18 and 19: viiiAppendix TablePageTable A.5 Det
Page 20 and 21: iiiThe authors would also like to t
Page 22 and 23: 2but also what material properties
Page 24 and 25: 4microstructure of the metal. The c
Page 26 and 27: 62. LITERATURE SEARCHBefore experim
Page 28 and 29: 8imperfections, the performance of
Page 30 and 31: 10wrought iron. Adding the slag aft
Page 32 and 33: 12method for manufacturing wrought
Page 34 and 35: 14patents for their process and tra
Page 36 and 37: 16This method of testing of structu
Page 38 and 39: 18plot of this percent elongation d
Page 40 and 41: 20significant variation in the perc
Page 42 and 43: 22The practice of restoring histori
Page 44 and 45: 24Elleby, Wallace W. Sanders, F. Wa
Page 46 and 47: 26From all the surveys that were di
Page 48 and 49: 28Table 2.1 Average Ultimate Streng
Page 50 and 51: 30Figure 2.3 Wrought Iron “Sponge
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32Histogram of Kirkaldy Wrought Iro
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34Percent Occurance in Range - %45.
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3660Combined Wrought Iron BarsTensi
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38The Bell Ford Bridge consisted of
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40Two. These samples were taken fro
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42specimens were of constant cross
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44Along with rectangular tensile co
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46After the initial test loading wa
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483.6 Fatigue TestingTo develop a b
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50The final specimen category consi
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52This analysis was completed using
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54After the initial test was comple
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56completed, but before the surface
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58readings, load cell readings and
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60Figure 3.3 Donated Eyebars 4 and
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62Figure 3.7 Heated Areas in Blue o
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64Figure 3.11 Detail Used in Groove
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66900080007000y = 27.153xR 2 = 0.99
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68Figure 3.19 Charpy Impact Testing
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70Figure 3.23 Eyebar Connection in
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72Figure 3.27 Eyebar A After Filler
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74Figure 3.31 Side View of Finished
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76Figure 3.35 Front View of Eyebar
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78strength from the existence of pe
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80The carbon content present in the
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82value may not be very accurate bu
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84strengths was found to be 29,940
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86wrought iron bars were investigat
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88stresses are induced. These perma
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90toughness the material. The test
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92From the finite element analysis,
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94Table 4.1 Chemical Analysis of Ey
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96Table 4.3 Tensile Coupon Test Res
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98Table 4.5 Charpy Impact Test Resu
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100Table 4.7 Comparison of Strain G
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102Figure 4.1 Typical Micrograph of
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104Figure 4.5 Fracture Surface of D
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106Comparison of Tensile Strengthfo
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108Combined Wrought Iron Bar Histor
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110Figure 4.17 Macrograph of Weld u
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112Figure 4.21 Cleavage Fracture of
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Figure 4.25 Elongation of Hole in E
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116signs on or near the bridge that
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118testing of historic wrought iron
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120so that they would act in symmet
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122The reasons for the differences
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124The second corrosion pattern mod
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126Keating (1984) stated that the s
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128charcoal fire until it is red ho
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130Figure 5.3 Picture of Bottom Cho
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132Figure 5.7 Using Force After Usi
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134Figure 5.11 Reassembling a Pin C
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1366. SUMMARY, CONCLUSIONS AND IMPL
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138rectangular in shape. These eyeb
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140were joined together with a full
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1424. The Charpy impact energy of t
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144connections are unsymmetrical, i
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146LIST OF REFERENCESAASHTO (1998).
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148Hodgkinson, Eaton (1840). Experi
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150Appendix A. Data Collected From
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152Table A.1 Wrought Iron Bar Tensi
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154Table A.1 (continued) Wrought Ir
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156Table A.2 (continued) Wrought Ir
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158Table A.3 Wrought Iron Angle Ten
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160Table A.4 (continued) Summary of
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162Table A.4 (continued) Summary of
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164Table A.5 (continued) Detailed I
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184Table A.7 Tensile Strength Data
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186Table B.1 Example Historic Wroug
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188DepartmentofTransportationIf you
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190CountyIf your organizationdoes m
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192County 16: County bridge inspect
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194State 13: Included in original d
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196Figure C.1 Diagrams Showing Loca
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198Figure C.3 Heating of Eyebar fro
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200Figure C.7 Double V Butt Joint u
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202Figure C. 11 Welded Tensile Coup
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204Figure C.15 Tensile Coupon from
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206Figure C.19 Cooling Bath with Su
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208Figure C.23 Side View of Eyebar
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210Figure C.27 Eyebar End Connectio
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212Appendix D. Welding Procedure fo
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214D.2 Filler Weld for Eyebar Conne
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216Figure D.1 Weld Joint Detail Use
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Figure D.5 Completed Weld Before Su
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220Figure D.7 Initial Pass Pattern
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