Evaluation and Repair of Wrought Iron and - Purdue e-Pubs ...

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vPageCHAPTER 3TEST PROCEDURES FOR MECHANICAL AND CONNECTION TESTS ...........373.1 Material Utilized in Testing.............................................................................373.2 Microstructure..................................................................................................383.3 Chemical Analysis ...........................................................................................393.4 Hardness Testing..............................................................................................403.5 Tensile Coupon Testing ...................................................................................403.5.1 Specimens Used in Tensile Coupon Testing .......................................403.5.2 Testing Procedure for Tensile Coupon Testing ...................................443.5.3 Type of Data Collected from Tensile Coupon Testing........................463.6 Fatigue Testing.................................................................................................483.7 Charpy Impact Testing.....................................................................................483.8 Eyebar Connection Testing..............................................................................513.9 Eyebar Connection Testing with Filler Weld ..................................................54CHAPTER 4 PRESENTATION OF TEST RESULTS...................................................774.1 Microstructure..................................................................................................774.2 Chemical Analysis ...........................................................................................794.3 Hardness Test Results......................................................................................814.4 Tensile Coupon Test Results ...........................................................................824.4.1 Resulting Fracture Surfaces .................................................................824.4.2 Overall Results from Tensile Testing ..................................................834.4.3 Comparison of Overall Results to Historical Data ..............................854.4.4 Results of the Heat Straightened Specimens .......................................874.4.5 Results of the Mechanically Straightened Specimen...........................874.4.6 Results of Welded Specimens..............................................................884.5 Fatigue Test Results.........................................................................................894.6 Charpy Impact Test Results.............................................................................894.7 Typical Eyebar Connection Testing Results....................................................91
viPage4.8 Repaired Eyebar Connection Testing Results..................................................93CHAPTER 5 REPAIR AND REHABILITION RECOMMENDATIONS...................1155.1 Determination of Material Properties of Bridge Members............................1155.2 Verification and Repair of Connection Symmetry ........................................1185.3 Damaged Pin Replacement............................................................................1195.4 Investigation of Crack Growth in Eyebars.....................................................1205.5 Evaluation and Repair of Corrosion Damage ................................................1235.6 Investigation and Repair of Elongated Eyebars and Diagonal Bracing.........1255.7 Investigation and Repair of Damaged and Bent Members ............................127CHAPTER 6 SUMMARY, CONCLUSIONS AND IMPLEMENTATION ................1366.1 Summary........................................................................................................1366.1.1 Summary of Literature Search...........................................................1366.1.2 Summary of Testing Results..............................................................1376.2 Conclusions....................................................................................................1416.3 Implementation of Inspection and Repair Recommendations.......................143LIST OF REFERENCES.................................................................................................146APPENDICES ............................................................................................................150Appendix A. Data Collected From Historical Studies..............................................150Appendix B. Survey Results.....................................................................................185Appendix C. Supplementary Photographs of Experimental Testing........................195Appendix D. Welding Procedure for Wrought Iron Tension Members ...................212D.1 Groove Weld with Double-V Connection Butt Joint………………………212D.2 Filler Weld for Eyebar Connection Corrosion Repair……………………..214
Page 1 and 2: Purdue UniversityPurdue e-PubsJTRP
Page 3: 1. Report No. 2. Government Accessi
Page 6 and 7: epairing a bent wrought iron tensio
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
Page 52 and 53: 32Histogram of Kirkaldy Wrought Iro
Page 54 and 55: 34Percent Occurance in Range - %45.
Page 56 and 57: 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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