US Army Corps of Engineer Inspection Evaluation And Repair Of Hydraulic Steel Structures

EM 1110-2-6054 1 December 2001 US Army Corps of Engineersfi ENGINEERING AND DESIGN Inspection, Evaluation, and Repair of Hydraulic Steel Structures ENGINEER MANUAL AVAILABILITY Electronic copies of this and other U.S. Army Corps of Engineers (USACE) publications are available on the Internet at http://www.usace.army.mil/inet/usace-docs/. This site is the only repository for all official USACE engineer regulations, circulars, manuals, and other documents originating from HQUSACE. Publications are provided in portable document format (PDF). DEPARTMENT OF THE ARMY EM 1110-2-6054 U.S. Army Corps of Engineers CECW-ED Washington, DC 20314-1000 Manual No. 1110-2-6054 1 December 2001 Engineering and Design INSPECTION, EVALUATION AND REPAIR OF HYDRAULIC STEEL STRUCTURES 1. Purpose. This manual describes the inspection, evaluation, and repair of hydraulic steel structures, including preinspection identification of critical locations (such as fracture critical members and various connections) that require close examination. Nondestructive testing techniques that may be used during periodic inspections or detailed structural inspections are discussed. Guidance is provided on material testing to determine the chemistry, strength, ductility, hardness, and toughness of the base and weld metal. Analyses methods that can be used to determine structure safety, safe inspection intervals, and expected remaining life of the structure with given operational demands are presented. Finally, considerations for various types of repair are discussed. 2. Applicability. This manual applies to all USACE commands having responsibilities for the design of civil works projects. 3. Distribution Statement. Approved for public release; distribution is unlimited. 4. Scope of the Manual. Chapter 1 describes the types of hydraulic steel structures. Chapter 2 discusses the causes of structural deterioration. Chapter 3 describes periodic inspection procedures, which are primarily visual. If the inspection indicates that a structure is distressed, nondestructive or destructive testing, described in Chapters 4 and 5, respectively, may be required. Chapter 6 describes the evaluation of the capability of a structure to perform its intended function. Chapter 7 discusses the determination of fracture toughness, and Chapter 8 describes repairs. FOR THE COMMANDER: 1 Appendix (See Table of Contents) ROBERT CREAR Colonel, Corps of Engineers Chief of Staff This manual supersedes ETL 1110-2-346, 30 September 1993, and ETL 1110-2-351, 31 March 1994. DEPARTMENT OF THE ARMY EM 1110-2-6054 U.S. Army Corps of Engineers CECW-ED Washington, DC 20314-1000 Manual No. 1110-2-6054 1 December 2001 Engineering and Design INSPECTION, EVALUATION AND REPAIR OF HYDRAULIC STEEL STRUCTURES Subject Paragraph Page Chapter 1 Introduction Purpose ...........................................................................................................................1-1 1-1 Applicability ..................................................................................................................1-2 1-1 Distribution ....................................................................................................................1-3 1-1 References ......................................................................................................................1-4 1-1 Background ....................................................................................................................1-5 1-1 Mandatory Requirements ...............................................................................................1-6 1-4 Chapter 2 Causes of Structural Deterioration Corrosion .......................................................................................................................2-1 2-1 Fracture ..........................................................................................................................2-2 2-3 Fatigue ............................................................................................................................2-3 2-5 Design Deficiencies........................................................................................................2-4 2-14 Fabrication Discontinuities.............................................................................................2-5 2-15 Operation and Maintenance............................................................................................2-6 2-15 Unforeseen Loading........................................................................................................2-7 2-16 Chapter 3 Periodic Inspection Purpose of Inspection .....................................................................................................3-1 3-1 Inspection Procedures ....................................................................................................3-2 3-1 Critical Members and Connections ................................................................................3-3 3-2 Visual Inspection ...........................................................................................................3-4 3-13 Critical Area Checklist ...................................................................................................3-5 3-13 Inspection Intervals ........................................................................................................3-6 3-14 Chapter 4 Detailed Inspection Introduction.....................................................................................................................4-1 4-1 Purpose of Inspection .....................................................................................................4-2 4-1 Inspection Procedures ....................................................................................................4-3 4-1 Inspector Qualifications..................................................................................................4-4 4-5 Summary of NDT Methods.............................................................................................4-5 4-6 Discontinuity Acceptance Criteria for Weldments.........................................................4-6 4-8 i EM 1110-2-6054 1 Dec 01 Subject Paragraph Page Chapter 5 Material and Weld Testing Purpose of Testing .........................................................................................................5-1 5-1 Selection of Samples from Existing Structure ...............................................................5-2 5-1 Chemical Analysis..........................................................................................................5-3 5-1 Tension Test ...................................................................................................................5-4 5-1 Bend Test .......................................................................................................................5-5 5-2 Fillet Weld Shear Test ...................................................................................................5-6 5-3 Hardness Test .................................................................................................................5-7 5-3 Fracture Toughness Test ................................................................................................5-8 5-4 Chapter 6 Structural Evaluation Purpose of Evaluation ....................................................................................................6-1 6-1 Fracture Behavior of Steel Materials .............................................................................6-2 6-1 Fracture Analysis ...........................................................................................................6-3 6-1 Linear-Elastic Fracture Mechanics ................................................................................6-4 6-7 Elastic-Plastic Fracture Assessment ...............................................................................6-5 6-7 Fatigue Analysis .............................................................................................................6-6 6-13 Fatigue Crack-Propagation .............................................................................................6-7 6-14 Fatigue Assessment Procedures......................................................................................6-8 6-17 Evaluation of Corrosion Damage....................................................................................6-9 6-19 Evaluation of Plastically Deformed Members................................................................6-10 6-20 Development of Inspection Schedules............................................................................6-11 6-20 Recommended Solutions for Distressed Structures........................................................6-12 6-20 Chapter 7 Examples and Material Standards Determination of Fracture Toughness.............................................................................7-1 7-1 Example Fracture Analysis.............................................................................................7-2 7-4 Example Fatigue Analysis ..............................................................................................7-3 7-12 Example of Fracture and Fatigue Evaluation..................................................................7-4 7-14 Structural Steels Used on Older Hydraulic Steel Structures ..........................................7-5 7-18 Chapter 8 Repair Considerations General............................................................................................................................8-1 8-1 Corrosion Considerations ...............................................................................................8-2 8-1 Detailing to Avoid Fracture ...........................................................................................8-3 8-2 Repair of Cracks ............................................................................................................8-4 8-3 Rivet Replacement .........................................................................................................8-5 8-8 Repair Examples ............................................................................................................8-6 8-8 Appendix A References ii ... - tailieumienphi.vn