MAT 540 : Composite Design

Fall 2012

Composite Bridge Design Project

Final Design Review By

Ninad Joshi
Kevin Hoos
Tengfei Yang
Overview of Presentation
 Bridge Info
 Materials Selection
 Stress Analysis
 Global Loads
 Critical Joints
 Manufacturing and Tooling
 Assembly
 Durability, Environmental Exposure, and
Repair
 Costing
 Certification
 Preliminary Design

 Material Selection

 Tooling And Manufacturing

Presented by Ninad Joshi

Bridge Info
 The bridge to be built will be located on
Interstate 675 west of North Fairfield Road.

 The purpose of the bridge is to provide a safe

transport for pedestrians and bicyclists to
attractions on both side of the Highways.
 Total Length: 520ft

178 ft. 176 ft.

Height:16ft 166 ft.

Width: 16ft
Design Approach
 Material Selection
 The goal of material selection is to minimize the cost while
meeting product performance goals.
 Factors Affecting Material Selection:
 Mechanical Property Requirement
 Service Environment
 Life Requirements
 Manufacturing

 Cost
Applied Loads
 Dead load of the bridge super structure.
(Deck, fence, light poles etc.)
 Live load : 90 lb. / sq. ft. (As per AASHTO)
 From stress analysis it was found that the max
compression load 22 MPa, and Tensile load of 6 MPa .
 Service Vehicles: 10000 lb. (As
per AASHTO)
 Deflection Criteria : 1:400
Service Environment
 Moisture: Humid (76%) for portions of the year. Fair
amount of rain every year. Snow and ice storm
yearly.
 Temperature : Min : -15 °F ( -26 °C)
Max: 105 °F (40.5 °C)
Large Single Day temperature swings.
 Lightning Strike Possible, brief high winds from
severe weather possible.
Life Requirements

 The life requirement for a bridge is usually more

than 50 years. While considering life span of the
bridge the environmental factors, fatigue, loss of
properties due to UV degradation, physical
damages should be considered.
Manufacturing

 While selecting materials the manufacturing

process should be considered. For example,
while considering manufacturing of composite
material by VARTM, the resin should be
selected such that it fulfills the viscosity
requirements for the process.
Cost

 Cost is the most important factor in the materials

selection. A product can be made using premium
quality material giving very high properties but if the
cost of the material is higher than the benefits
received from using the premium materials, then
the material selection should be changed unless
cost is not a factor.
 Preliminary Design

 Material Selection

 Tooling And Manufacturing

Presented by Ninad Joshi

 Material Selection
 Available materials are
 Steel :
 Concrete
 Composites
 Light Weight
 Good Environmental
Resistance
 Low repairing cost
Material Selection

Materials
Glass Fiber ( S Glass) Balsa Wood


 For Beam supporting  Core for beam

Bridge
supporting Bridge
 Bridge Deck
 Vinyl Ester
 Bridge Sub Deck
 Bridge Deck
 Epoxy (Hexcel 3501-6)
 For Beam Supporting
 Steel
Bridge  To join the beams (A-36)
 Bridge Sub Deck
 Stress Analysis
 Global Loads
 Critical Joints

 Assembly

Presented by Kevin Hoos

 Stress Analysis

Kevin Hoos
 Loads on Structure
 Design Pedestrian Load –

90 lb/ft2
 Load of Deck Material – 15 lb/ft2
 Preliminary Attachments – 160 lb/ft
span
 Fencing
From AASHTO LRFD Design Manual

 Lights
 Beam Theory

Equations from Beer’s Mechanics of Materials 5th Ed.

 Finite Element Analysis

Solidworks & Abaqus CAE & Abaqus

Category Weight
Solidworks Simulation Standard

Meshing Quality 0.09 2 4

Element Types 0.01 1 4

Problem Setup Features 0.1 4 4.5

Accessibility 0.2 5 3

Results Output 0.1 4 3

Ease of Use 0.5 5 2

Total   4.49 2.75

Deflection of Beam in Bending

Maximum Deflection – 120 mm

Deflection Ratio – L/455
Stresses In Flange Plate

Maximum Von Mises Stress – 14.1 MPa

Yield Stress – 250 MPa
Yield Stress from Steel Construction Manual, 8th Edition
Deflection in Total Bridge Span

Maximum Deflection – 75.0 mm

Deflection Ratio – L/723
 Preliminary Design

 Material Selection

 Tooling And Manufacturing

Presented by Ninad Joshi

Tooling And Manufacturing
 Due to material selection, feasible manufacturing
method is Prepreg/Autoclave.
 Selected Fiber Layup for top and bottom flange is
[[04/±452]2/04]s and lay up for webs is [±4510] s
 Beams will be manufactured in 40 ft. sections.
 Metal plated used to join the bridge sections are
inserted into the balsa before molding operation.
Tooling and Manufacturing
Tooling and Manufacturing
 The sub deck will be manufactured using the
same materials. As sub deck transfers the load
from the deck to the beam and supports the
load of fencing, light pole, a quasi isotropic
layup should be used.

 The Deck is a bought out item. It is made using

VARTM using vinyl ester resin.
Stress Analysis
 Global Loads
 Critical Joints

Assembly

Presented by Kevin Hoos

 Assembly

 Take advantage of Accelerated Bridge construction

 Fabricate and assemble as much as possible in
factory
Optimize transportation cost
Minimize impact on surrounding area
 Factory Assembly

 Composite Beams
 Sub-Deck

 Deck

 Attachment Flanges
drilled and tapped From http://www.bikerumor.com/2012/05/17/enve-composites-factory-
tour-inside-look-at-company-carbon-fiber-manufacturing/
 On-Site Assembly

 Assemble Beams,
Subdeck, and Deck into
200 ft sections
 Place North and South
Sections
From FWHA’s ABC Manual

 Place Center Section and

bolt in place
 Durability, Environmental
Exposure

 Repairing

 Costing

 Certification

Presented by Tengfei Yang

 Durability
 Outstanding durability
 Outstanding Durability means long life and minimal
maintenance.

Deficiencies were mainly due to environmental effects:

 Corrosion
 Fire
 Earthquake
 Wide Temperature Range
 Temperature Range in Ohio
- 15 F0 during winter 105 F 0 during summer
 Rainwater Corrosion
 The most acidic rain in the U.S. is in

Pennsylvania (average pH of rainfall

4.1), Ohio, and New York.

 These states are downwind of the big

industrial cities in Illinois, Michigan, Indiana,

Ohio, and Pennsylvania (including Pittsburgh).

 The industries found in these cities contribute

many of the air pollutants that create acid rain.

 Other Factors About the Durability

 Also, as time went by

increased social needs such
as traffic loads, design codes,
and increased safety features.
 Our bridge is built over I-675
West of North Fairfield Road,
which would be widely used
for the people there go across
I-675
 Composite Steel

Not so good as composite

Acid Rain Good enough for out bridge
materials resistant chemical
Corrosion choice
corrosion

Low CTE and have enough

Temperatur Good enough to defend the
stiffness and strength even in
e range bad weather in OH
a big range of temperature

Design
> 50 years > 50 years
serving life
 Repairing
For composite bridge, it is very easy to repair when some parts
are broken by humans or natural forces mainly because of its
light weight
 Cover Broken: make new composite patch on it which has
components before
 Deck or Beam Broken:
As we design, each deck and beam is not very big but strong,
once one of them is broken, we can just order a new one and
renewal it, it takes only in a few hours
 Costing
For costing of bridge, we separate it into several
parts.
 Material costs
 Manufacture costs
 Labor costs
 Transportation costs
 Repair costs
 Material Cost: Deck, Beams and Concretes

deck
deck
6.000’
6.000’

0.13’
0.13’
beam
beam
 Our Beams Composites

Volume factor (f) Density(P) Price (s)

E-glass fiber 0.45 0.092 1 dollar/pound

Epoxy
0.55 0.046 4dollar/pound
matrix
Total 1

Coste-glass= Ve*fe*Pe*se*(three parts)*(number of

beams)=601595*0.45*0.092*3*4 = 298,872 dollars
Costepoxy= Vy*fy*Py*sy*(three parts)*(number of
beams)=601595*0.55*0.046*4*3*4=730,577 dollars
Costbalsa=0.55*(5.74*1.74*520*4)/(0.125*0.5848)

= 156,303 dollars
 Decking Area (square Price (per Total
foot) square foot) cost(dollar)
Decking
Glass/fiber cost14.250*520 50 370,500

wide
 Concrete Cost
Concrete Mixes:
2500 PSI AE $ 84.00 per cubic yard
3000 PSI AE $ 85.00 per cubic yard
3500 PSI AE $ 87.00 per cubic yard
4000 PSI AE $ 88.00 per cubic yard
Class C AE $ 90.00 per cubic yard

The hole volume for the pier of the bridge should be

16*17*15=4080 cubic feet per pier.

Cost =4080/27*2*88=26596 dollars
The total material costs is

298,872+730,577+370,500+156,303+26596 =
1,582,848dollars
 Manufacturing Cost
 The structures can easily range from
 350---2000 Dollars/ linear foot(data apply by Excel
bridge company)
 Depends on the
 Usage,
 Aesthetics
 Applicable Codes
 Other options
 we get the price of $1000 / linear foot.
 So the cost of Manufacture cost: 520*1000=520,000
dollars
 Transports Cost
 Here we cost the cost of transport by the weight and miles spend.
 For Balsa the weight is calculated as 471 tons and the epoxy/fiber
is 515tons , so we got about 986 almost 1000 tons for the beams.
The material for concrete and upside decking is about 2 times
weight than the beams, the total weight would be about 3000
tons.
 The stand truck is usually 20 tons limited and about 2000 dollars
per truck cost(depends on the Eastern region of USA and the
miles cost for table 1, and we get the cost of transport as
(3000/20)*2000=300,000
 Repair Cost
 Repair can be divided by several parts as below:
 PCI beam end repair:
2000/simple repair ; 4000/extensive repairs
 structural composite(plus partial painting
cost):

2400/bolted 6200/welded (iron)

 Repairing

 The percent of broken needs to be fixed is usually

5% for bridges and the bridge is design for using 50
years so we got :
 (2400*3*5%+4*2000*5%)*50=38,000 dollars
 Other costs
 Manufacturing costs : $520,000

 Labor costs: 50 workers for one day pay at an

average of 20 dollars/hour for

8hours, and Costlabor= 8000 dollars

 Transport costs : about 300,000 dollars

 Repair costs : 38,000 for 50 years

 Total Cost : Around $ 2.5 Million

 Certification
 The effects of temperature and moisture are accounted for
in design values and strength properties.
 Features (3501-6 epoxy matrix)
 Service temperature up to 350°F (177°C)
 Damage-resistant system
 350°F (177°C) cure
 Certification

 Neat Resin Properties

 Density 1.265 gm/cc
 Tg dry 6 hr 350°F (177°C) cure 410°F
(210°C)
 Tg wet 6 hr 350°F (177°C) cure 304°F
(151°C)
 3501-6 (Epoxy) Properties
 Tensile strength 6.6 ksi
 Tensile modulus 0.615
msi
 Tensile elongation 1.10%
 Shear strength 7.0 ksi
 Shear elongation to
failure 1.95%
 Flexural modulus 484 ksi
 Poisson’s ratio 36.50%
 Strain energy release
rate, G1C 0.733 in-lb/in2
 Gel time @ 350°F (177°C)
4–10 minutes
 Minimum viscosity 4.0
Poise
 Coefficient of thermal
expansion (CTE)
---RT–163°F (RT–
73°C) 21.1 x 106/°F
---160–250°F (71–
121°C) 24.4 x 106/°F
---250–350°F (121–
177°C) 33.3 x 106/°F
Thank you for your
Attention !