Development of a TL-3 Deep Beam Tubular Backup Bridge Rail

Development of a TL-3 Deep Beam Tubular Backup Bridge Rail
Final Report
Prepared by
Akram Y. Abu-Odeh, Ph.D.
Research Scientist
Texas Transportation Institute
William F. Williams, P.E.
Associate Research Engineer
Texas Transportation Institute
C. Eugene Buth, Ph.D., P.E.
Senior Research Fellow
Texas Transportation Institute
and
Kang-Mi Kim, Ph.D.
Post Doctoral Research Associate
Texas Transportation Institute
Final Report
Report 476890-1
Project 476890-01
Prepared in cooperation with the
Ohio Department of Transportation
and the
U.S. Department of Transportation, Federal Highway Administration
TABLE OF CONTENTS
Page
LIST OF FIGURES . ix
LIST OF TABLES . xi
1. INTRODUCTION 1
1.1. STATEMENT OF THE PROBLEM .1
1.2. FOCUS OF THE STUDY 1
2. RESEARCH OBJECTIVES .3
2.1. PHASE 1 3
2.1.1 Task 1 3
2.1.2 Task 2 3
2.2. PHASE 2 4
2.2.1 Task 1 4
2.2.2 Task 2 4
2.3. REPORT SCOPE .5
3. LITERATURE REVIEW .7
3.1. BACKGROUND OF BRIDGE RAIL DESIGN GUIDELINES .7
3.2. SIGNIFICANCE OF WORK .7
3.3. BACKGROUND OF FINITE ELEMENT ANALYSIS 14
4. ENGINEERING REVIEW, ANALYSIS, AND MODIFICATION OF THE OHIO DEEP
BEAM BRIDGE RAIL 17
5. FINITE ELEMENT ANALYSIS OF ODOT DEEP BEAM BRIDGE RAIL .21
5.1. STRENGTH EVALUATION OF POST-DECK SUB-SYSTEM .21
5.1.1 Post-Deck Model 21
5.1.2 Results of Post-Deck Model or Pendulum (Impactor) Model 23
5.2. FULL SYSTEM PERFORMANCE EVALUATION 26
5.2.1 Full System Model 26
5.2.2 Full System Performance with Pavement Overlay using 3-11 Test Conditions .31
5.2.3 Full System Performance with Pavement Overlay using 3-10 Test Conditions .37
5.2.4 Full System Performance without Pavement Overlay using 3-10 Test Conditions 42
6. CONCLUSIONS AND RECOMMENDATIONS .47
7. IMPLEMENTATION PLAN .49viii
TABLE OF CONTENTS (CONTINUED)
Page
REFERENCES 51
APPENDIX A ODOT STANDARD BRIDGE DRAWING DBR-2-73 53
APPENDIX B ANALYSIS OF ODOT MODIFIED BRIDGE RAIL .57
APPENDIX C DRAWINGS OF ODOT MODIFIED BRIDGE RAIL USED IN FEM .71
C1. ODOT MODIFIED BRIDGE RAIL WITH OVERLAY 71
C2. ODOT MODIFIED BRIDGE RAIL WITHOUT OVERLAY 83
APPENDIX D DRAWINGS OF ODOT MODIFIED BRIDGE RAIL WITH PAVEMENT
OVERLAY 95
APPENDIX E THE ODOT GR-3.4 TRANSITION ASSEMBLY 107
LIST OF FIGURES
Page
Figure 3.1 ODOT Deep Beam bridge rail (a) Type 1 post and (b) Type 2 post (1) . 8
Figure 3.2 Texas Type T101 bridge rail (9) . 9
Figure 3.3 TxDOT Type T101 bridge rail section (12) 10
Figure 3.4 The Illinois side-mounted bridge rail (7) 11
Figure 3.5 Damage at a post of the Illinois rail after a PL-2 test with a pickup (7) . 12
Figure 3.6 Oregon side-mounted bridge rail installation (8) 13
Figure 3.7 Damage to the Oregon side-mounted rail after PL-1 pickup test (8) 14
Figure 3.8 Test and simulation of concrete barrier and deck (14) . 15
Figure 3.9 Model and physical setup of the New York transition to tubular
bridge rail (15) 15
Figure 4.1 Section through the suggested (retrofit) rail at post location 17
Figure 4.2 Section through the suggested (retrofit) rail in between posts 18
Figure 4.3 Retrofit with a shim plate at the post section 18
Figure 4.4 TTI drawing of the deck rebar (layout) . 19
Figure 4.5 TTI drawing of the deck rebar (cross section) 19
Figure 5.1 Pendulum impact setup for the post-anchor-deck assembly . 21
Figure 5.2 Model view showing the reinforcement and anchor details of the deck . 22
Figure 5.3 Concrete deck model and mesh 22
Figure 5.4 Initialized force in the anchors to represent the connectivity
of the nuts (torque) (Unit: Newton) 23
Figure 5.5 Post-deck assembly after impact . 23
Figure 5.6 Damage to the concrete deck 24
Figure 5.7 Maximum plastic strain distribution in the post assembly 24
Figure 5.8 Anchor forces (Unit: Newton) 25
Figure 5.9 Maximum axial stress in the deck steel reinforcement (Unit: N/mm2) 25
Figure 5.10 Impact force history 26
Figure 5.11 Anchors inflection points and boundary conditions . 27
Figure 5.12 Close up of the full system model . 27
Figure 5.13 W-beam model from the GR-2.2 model (arrows point to the pre-bent
geometry) 28
Figure 5.14 Reconstructed W-beam model to be implemented in the Deep Beam
rail system . 28
Figure 5.15 Model setup with 3-inch thick pavement overlay . 29
Figure 5.16 Close up on setup showing lower box rail (rub rail) with pavement 29
Figure 5.17 View of the model showing the meshing details with pavement 29
Figure 5.18 C2500 (reduced truck model) similar to the one used in the GR-2.2 simulation . 30
Figure 5.19 C2500 (detailed truck model) to be used in the Deep Beam bridge rail
system simulation 30
Figure 5.20 820C test vehicle model 31
Figure 5.21 Gut view (looking upstream) showing 2000P test vehicle interacting with the
modified deep beam system from initial impact till exit and rolling back . 32
Figure 5.22 Vehicle dynamics at maximum roll angle 32x
LIST OF FIGURES (CONTINUED)
Page
Figure 5.23 Signal data from TRAP of the 2000P FE model . 33
Figure 5.24 X acceleration history at the C.G. of the 2000P FE model . 34
Figure 5.25 Y acceleration history at the C.G. of the 2000P FE model . 34
Figure 5.26 Z acceleration histories at the C.G. of the 2000P FE model . 35
Figure 5.27 Vehicle angular displacements for test 3-11 simulation . 35
Figure 5.28 Summary of results of NCHRP Report 350 test 3-11 simulation . 36
Figure 5.29 Sequential images of the 820C vehicle interaction with the bridge rail model
with pavement overlay 37
Figure 5.30 Signal data from TRAP of the 820C model impacting the bridge rail with
pavement overlay 38
Figure 5.31 X acceleration history at the C.G. of the 820C FE model with pavement 39
Figure 5.32 Y acceleration history at the C.G. of the 820C FE model with pavement 39
Figure 5.33 Z acceleration history at the C.G. of the 820C FE model with pavement 40
Figure 5.34 Vehicle angular displacements for the 820C FE model with pavement . 40
Figure 5.35 Summary of results of NCHRP Report 350 test 3-10 simulation of the
bridge rail with pavement overlay 41
Figure 5.36 Sequential images of the impact vehicle interaction of the bridge rail model
without pavement 42
Figure 5.37 Signal data from TRAP of the 820C model impacting the bridge rail without
pavement overlay 43
Figure 5.38 X acceleration history at the C.G. of the 820C FE model without pavement . 44
Figure 5.39 Y acceleration history at the C.G. of the 820C FE model without pavement . 44
Figure 5.40 Z acceleration history at the C.G. of the 820C FE model without pavement . 45
Figure 5.41 Vehicle angular displacements for the 820C FE model without pavement 45
Figure 5.42 Summary of results of NCHRP Report 350 test 3-10 simulation of the
bridge rail without pavement overlay . 46
Figure 6.1 Comparison of design of the ODOT Deep Beam bridge rail 47
Figure 7.1 NY DOT bridge rail transition (15) 49xi
LIST OF TABLES
Page
Table 3.1 Condition of TL-3 for longitudinal barrier 7
Table 3.2 Condition of PL-1 and PL-2 for longitudinal barrier . 7
Table 4.1 Bridge rail test levels and crash test criteria (AASHTO LRFD Table 13.7.2-1) (4). 20
Table 4.2 Design forces for traffic railings (AASHTO LRFD Table A13.2-1) (4) 20
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