Research on an innovative structure of an open-ribbed steel–ultra-high performance concrete composite bridge deck

Abstract

To completely solve the problem of fatigue cracking issue of orthotropic steel bridge decks (OSDs), the authors proposed a steel–ultra-high performance concrete (UHPC) lightweight composite deck (LWCD) with closed ribs in 2010. Based on the successful application of that LWCD, an adaptation incorporating an innovative composite deck structure, i.e., the hot-rolled section steel–UHPC composite deck with open ribs (SSD) is proposed in this paper, aiming to simplify the fabrication process as well as to reduce the cost of LWCD. Based on a long-span cable-stayed bridge, a design scheme is proposed and is compared with the conventional OSD scheme. Further, a finite element (FE) calculation is conducted to reflect both the global and local behavior of the SSD scheme, and it is found that the peaked stresses in the SSD components are less than the corresponding allowable values. A static test is performed for an SSD strip specimen to understand the anti-cracking behavior of the UHPC layer under negative bending moments. The static test results indicate that the UHPC layer exhibited a satisfactory tensile toughness, the UHPC tensile strength obtained from the test is 1.8 times the calculated stress by the FE model of the real bridge. In addition, the fatigue stresses of typical fatigue-prone details in the SSD are calculated and evaluated, and the influences of key design parameters on the fatigue performance of the SSD are analyzed. According to the fatigue results, the peaked stress ranges for all of the 10 fatigue-prone details are within the corresponding constant amplitude fatigue limits. Then a fatigue test is carried out for another SSD strip specimen to explore the fatigue behavior of the fillet weld between the longitudinal and transverse ribs. The specimen failed at the fillet weld after equivalent 47.5 million cycles of loading under the design fatigue stress range, indicating that the fatigue performance of the SSD could meet the fatigue design requirement. Theoretical calculations and experiments provide a basis for the promotion and application of this structure in bridge engineering.

Graphical abstract

Keywords

steel–ultra-high performance concrete composite deck / open rib / strip model test / static and fatigue performance / orthotropic steel deck

References

[1] AISC. Design Manual for Orthotropic Steel Plate Deck Bridges. New York: American Institute of Steel Construction, 1963

[2] Wolchuk R. Lessons from weld cracks in orthotropic decks on three European bridges. Journal of Structural Engineering, 1990, 116(1): 75–84

[3] Tsakopoulos P A, Fisher J W. Full-scale fatigue tests of steel orthotropic Decks for the Williamsburg bridge. Journal of Bridge Engineering, 2003, 8(5): 323–333

[4] Cao B Y, Ding Y L, Song Y S, Zhong W. Fatigue life evaluation for deck-rib welding details of orthotropic steel deck integrating mean stress effects. Journal of Bridge Engineering, 2019, 24(2): 04018114

[5] Xiao Z G, Yamada K, Inoue J, Yamaguchi K. Fatigue cracks in longitudinal ribs of steel orthotropic deck. International Journal of Fatigue, 2006, 28(4): 409–416

[6] Wu W, Kolstein H, Veljkovic M. Fatigue resistance of rib-to-deck welded joint in OSDs, analyzed by fracture mechanics. Journal of Constructional Steel Research, 2019, 162: 105700

[7] Li J, Zhang Q H, Bao Y, Zhu J, Chen L, Bu Y. An equivalent structural stress-based fatigue evaluation framework for rib-to-deck welded joints in orthotropic steel deck. Engineering Structures, 2019, 196: 109304

[8] Liu R, Liu Y Q, Ji B, Wang M, Tian Y. Hot spot stress analysis on rib–deck welded joint in orthotropic steel decks. Journal of Constructional Steel Research, 2014, 97(6): 1–9

[9] Fu Z Q, Ji B, Zhang C, Wang Q. Fatigue performance of roof and U-rib weld of orthotropic steel bridge deck with different penetration rates. Journal of Bridge Engineering, 2017, 22(6): 04017016

[10] Wang K, Jie Z, Liang S D, Zhuge P. Fatigue assessment of U-rib full penetration welded joints based on local methods. Journal of Constructional Steel Research, 2023, 200: 107684

[11] Fang Z, Ding Y, Wei X, Li A, Geng F. Fatigue failure and optimization of double-sided weld in orthotropic steel bridge decks. Engineering Failure Analysis, 2020, 116: 104750

[12] Heng J, Zheng K, Gou C, Zhang Y, Bao Y. Fatigue performance of rib-to-deck joints in orthotropic steel decks with thickened edge U-ribs. Journal of Bridge Engineering, 2017, 22(9): 04017059

[13] Luo P J, Zhang Q H, Bao Y Z, Bu Y. Fatigue performance of welded joint between thickened-edge U-rib and deck in orthotropic steel deck. Engineering Structures, 2019, 181: 699–710

[14] Wang B, Lu P, Shao Y. Research on rib-to-diaphragm welded connection by means of hot spot stress approach. Steel and Composite Structures, 2015, 18(1): 135–148

[15] Castiglioni C A, Fisher J W, Yen B T. Evaluation of fatigue cracking at cross diaphragms of a multigirder steel bridge. Journal of Constructional Steel Research, 1988, 9(2): 95–110

[16] Cui C, Hu J D, Zhang X, Zeng J, Li J, Zhang Q. Fatigue test and failure mechanism of new rib-to-floorbeam welded joints in OSDs. Journal of Constructional Steel Research, 2023, 203: 107835

[17] Connor R J. Influence of cutout geometry on stresses at welded rib-to-diaphragm connections in steel orthotropic bridge decks. Transportation Research Record: Journal of the Transportation Research Board, 2004, 1892(1): 78–87

[18] Zhu Z W, Xiang Z, Li J, Huang Y, Ruan S. Fatigue behavior of orthotropic bridge decks with two types of cutout geometry based on field monitoring and FEM analysis. Engineering Structures, 2020, 209: 109926

[19] Di J, Wang J, Zhou X, Peng X, Qin F. Fatigue behavior of rib-to-floor beam junctions with separate inner stiffeners in orthotropic steel bridge decks. Journal of Bridge Engineering, 2022, 27(5): 04022019

[20] Zhu A, Li M, Zhu H P, Xu G, Xiao H, Ge H. Fatigue behaviour of orthotropic steel bridge decks with inner bulkheads. Journal of Constructional Steel Research, 2018, 146(7): 63–75

[21] Li J P, Zhu Z W. Effects of full internal bulkheads on fatigue behaviors of orthotropic steel decks. Journal of Constructional Steel Research, 2022, 196: 107400

[22] Xiang Z, Zhu Z W. Fatigue behavior of orthotropic composite bridge decks without cutout at rib-to-floorbeam intersection. Journal of Constructional Steel Research, 2018, 146(7): 63–75

[23] Tai M, Arima Y, Shimozato T. Fatigue strength enhancement by structural modification of transverse to longitudinal rib connections in orthotropic steel decks with open ribs. Engineering Failure Analysis, 2020, 117: 104954

[24] He X, Wu C, Wang R, Wei L, Jiang C. Experimental study on buckling behavior of orthotropic steel deck with slender open ribs for large span suspension bridges. Journal of Constructional Steel Research, 2023, 201: 107681

[25] Zhang Q H, Liu Y, Bao Y, Jia D, Bu Y, Li Q. Fatigue performance of orthotropic steel−concrete composite deck with large-size longitudinal U-shape ribs. Engineering Structures, 2017, 150(11): 864–874

[26] Shao X D, Yi D T, Huang Z Y, Zhao H, Chen B, Liu M. Basic performance of the composite deck system composed of orthotropic steel deck and ultrathin RPC layer. Journal of Bridge Engineering, 2013, 18(5): 417–428

[27] Ding N, Shao X D. Study on fatigue performance of light-weighted composite bridge deck. China Civil Engineering Journal, 2015, 48(1): 74–81

[28] Zhang S H, Shao X D, Cao J H, Cui J, Hu J, Deng L. Fatigue performance of a lightweight composite bridge deck with open ribs. Journal of Bridge Engineering, 2016, 21(7): 04016039

[29] Pei B, Li L F, Shao X D, Wang L, Zeng Y. Field measurement and practical design of a lightweight composite bridge deck. Journal of Constructional Steel Research, 2018, 147(8): 564–574

[30] Luo J, Shao X D, Fan W, Cao J, Deng S. Flexural cracking behavior and crack width predictions of composite (steel + UHPC) lightweight deck system. Engineering Structures, 2019, 194(9): 120–137

[31] Luo J, Shao X D, Cao J H, Xiong M, Fan W. Transverse bending behavior of the steel–UHPC lightweight composite deck: Orthogonal test and analysis. Journal of Constructional Steel Research, 2019, 162(11): 105708

[32] Wang Y, Shao X D, Chen J, Cao J, Deng S. UHPC-based strengthening technique for orthotropic steel decks with significant fatigue cracking issues. Journal of Constructional Steel Research, 2021, 176: 106393

[33] Larrard F D, Sedran T. Optimization of ultra-high-performance concrete by the use of a packing model. Cement and Concrete Research, 1994, 24(6): 997–1009

[34] Shen X J, Brühwiler E. Influence of local fiber distribution on tensile behavior of strain hardening UHPFRC using NDT and DIC. Cement and Concrete Research, 2020, 132: 106042

[35] Feng J H, Shao X D, Qiu M H, Li H, Gao X, Huang Z. Reliability evaluation of flexural capacity design provision for UHPC beams reinforced with steel rebars/prestressing tendons. Engineering Structures, 2024, 300: 117160

[36] Chen S, Huang Y, Gu P, Wang J Y. Experimental study on fatigue performance of UHPC-orthotropic steel composite deck. Thin-walled Structures, 2019, 142: 1–18

[37] Xiang Z, Zhu Z W. Simulation study on fatigue behavior of wrap-around weld at rib-to-floorbeam joint in a steel–UHPC composite orthotropic bridge deck. Construction & Building Materials, 2021, 289(1): 123161

[38] Yuan Y, Wu C, Jiang X. Experimental study on the fatigue behavior of the orthotropic steel deck rehabilitated by UHPC overlay. Journal of Constructional Steel Research, 2019, 157(6): 1–9

[39] Wei C, Zhang Q H, Yang Z X, Li M, Cheng Z, Bao Y. Flexural cracking behavior of reinforced UHPC overlay in composite bridge deck with orthotropic steel deck under static and fatigue loads. Engineering Structures, 2022, 265(8): 114537

[40] Pan W H, Fan J S, Nie J G, Hu J H, Cui J F. Experimental study on tensile behavior of wet joints in a prefabricated composite deck system composed of orthotropic steel deck and ultrathin reactive-powder concrete layer. Journal of Bridge Engineering, 2016, 21(10): 04016064

[41] Shi Z C, Su Q, Kavoura F, Veljkovic M. Behavior of short-headed stud connectors in orthotropic steel–UHPC composite bridge deck under fatigue loading. International Journal of Fatigue, 2022, 160: 106845

[42] Cao J H, Shao X D, Deng L, Gan Y. Static and fatigue behavior of short-headed studs embedded in a thin ultrahigh-performance concrete layer. Journal of Bridge Engineering, 2017, 22(5): 04017005

[43] Qin S Q, Zhang J, Huang C L, Gao L, Bao Y. Fatigue performance evaluation of steel–UHPC composite orthotropic deck in a long-span cable-stayed bridge under in-service traffic. Engineering Structures, 2022, 254: 113875

[44] Di J, Ruan X Z, Zhou X H, Wang J, Peng X. Fatigue assessment of orthotropic steel bridge decks based on strain monitoring data. Engineering Structures, 2021, 228: 111437

[45] JTGD64-2015. Specifications of Design of Highway Steel Bridge. Beijing: Ministry of Transport of the People’s Republic of China, 2015

[46] HobbacherA F. Recommendations for Fatigue Design of Welded Joints and Components. 2nd ed. Villepinte: International Institute of Welding, 2016

[47] En1993-1-9. Eurocode 3: Design of Steel Structures-Part 1–9: Fatigue. Brussels: European Committee for Standardization, 2005

Acknowledgements

The authors gratefully thank the National Natural Science Foundation of China (Grant Nos. 52038003 and 51778223) and Technology R&D Plan of China Construction Fifth Engineering Division Co., Ltd. (No. CSCES5b-2022-12) for their financial support.

Competing interests

The authors declare that they have no competing interests.

RIGHTS & PERMISSIONS

2024 Higher Education Press