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2. TESTING

Testing Program

The testing program consisted of an evaluation of the following:

Upon conclusion, the researchers provided a summary of the testing program to the project Technical Advisory Panel, and the Panel provided comments. See section 3.

Materials

Publication FHWA-HIF-12-020, Laminate Specification and Characterization, describes the FRP materials considered and tested for this project. Appendices A through C provide addenda to the Laminate Specification and Characterization report. Appendix D summarizes the testing and selection of grout material.

Tube Subcomponents

Table 1 details the testing of the tube specimens, and Appendix E presents findings of these tests.

Table 1. Tube testing.
Test Type No. of Specimens (10-ft span) Description Purpose
1 1 Empty tube with strain gages to obtain load-deflection data. Calibrate finite element analysis.
2 1 Tube filled (wide cell) with the #1 choice of grout, tested with strain gages to obtain load-deflection data. Tested wide side up. Calibrate finite element analysis and assess performance of the bond interface. Compare performance of grouts.
3 1 Tube filled (narrow cell) with the #1 choice of grout, tested with strain gages to obtain load-deflection data. Tested wide side down. Same as above but with narrow cell filled.
4 1 Tube filled (wide cell) with the #2 choice of grout, tested with strain gages to obtain load-deflection data. Tested wide side up. Calibrate finite element analysis and assess performance of the bond interface. Compare performance of grouts.
5 1 Tube filled (narrow cell) with the #2 choice of grout, tested with strain gages to obtain load-deflection data. Tested wide side down. Same as above but with narrow cell filled.
6 3 Simple deflection test of a tube filled (wide cell) with the #1 choice of grout, tested wide side up, then wide side down. Check consistency of interface performance and relative performance of tube up vs. down.
7 3 Simple deflection test of a tube filled (narrow cell) with the #1 choice of grout, tested wide side up, then wide side down. Check consistency of interface performance and relative performance of tube up vs. down.
8 3 Simple deflection test of a tube filled (wide cell) with the #2 choice of grout, tested wide side up, then wide side down. Check consistency of interface performance and relative performance of tube up vs. down.
9 3 Simple deflection test of a tube filled (narrow cell) with the #2 choice of grout, tested wide side up, then wide side down. Check consistency of interface performance and relative performance of tube up vs. down.

Structural Panels

Twelve full-depth panels measuring 3 feet by 11 feet were tested to determine response under flexure, shear, and ultimate failure. The following describes the three panel types that were tested:

Documentation of the testing is presented in the following appendixes:

Assembly

Figures 1 through 7 illustrate the assembly of deck panels from tube subcomponents.

Photo. The pultruded tube subcomponent consisting of E-glass and vinyl ester resin
Figure 1. Photo. The pultruded tube subcomponent consisting of E-glass and vinyl ester resin.

Photo. Tube subcomponents are bonded together with adhesive to form a panel.
Figure 2. Photo. Tube subcomponents are bonded together with adhesive to form a panel.

Photo. Panel ends are capped and radii between tubes filled with thixotropic resin.
Figure 3. Photo. Panel ends are capped and radii between tubes filled with thixotropic resin.

Photo. The panel is wrapped in glass fiber in preparation for infusion with vinyl ester resin.
Figure 4. Photo. The panel is wrapped in glass fiber in preparation for infusion with vinyl ester resin.

Photo. Resin is infused for the outer wrap using a vacuum-assisted resin transfer molding (VARTM) method.
Figure 5. Photo. Resin is infused for the outer wrap using a vacuum-assisted resin transfer molding (VARTM) method.

Photo. Each infused deck panel is stripped and inspected to ensure that fibers have been thoroughly wet-out with resin.
Figure 6. Photo. Each infused deck panel is stripped and inspected to ensure that fibers have been thoroughly wet-out with resin.

Photo. Adhesive and stone are applied for course 1 of the wearing surface. (The black rectangle is a bearing pad for the bridge railing post.)
Figure 7. Photo. Adhesive and stone are applied for course 1 of the wearing surface. (The black rectangle is a bearing pad for the bridge railing post.)

Special testing categorized as “details” includes:

Documentation of these tests is provided as follows:

Appendix L provides the laboratory report for fire testing.

Page last modified on May 18, 2012.
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