7.2 Ingenieurbau
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Inspection and maintenance contribute significantly to the lifetime cost of bridges. There is significant potential in using information obtained through structural health monitoring to update predictive models of the condition and performance of such structures, and thus ena-ble an improved decision-making regarding inspection and maintenance activities. Within the AISTEC project funded by the German Federal Ministry of Education and Research, we develop vibration-based structural health monitoring systems aimed at continuously provid-ing information on the structural condition of bridges. Environmental variations such as changing ambient temperatures can significantly influence the dynamic characteristics of bridges and thus mask the effect of structural changes and damages. It remains a challenge to account for such influences in structural health monitoring. To study the effect of ambient temperatures on the dynamic characteristics of beam structures, we monitor the vibration response of a reinforced concrete beam in the uncracked and cracked state at varying tem-peratures in a climate chamber. We postulate a set of competing parameterized probabilistic structural models, which explicitly account for the effect of varying ambient temperatures on the mechanical properties of the system. We then combine the information provided by the structural models with the information contained in the recorded vibration data to learn the parameters of the temperature-dependent structural models and infer the plausible state of the beam using Bayesian system identification and model class selection.
Gradual or sudden changes in the state of structural systems caused, for example, by deterioration or accidental load events can influence their load-bearing capacity. Structural changes can be inferred from static and/or dynamic response data measured by structural health monitoring systems. However, they may be masked by variations in the structural response due to varying environmental conditions. Particularly, the interaction of nominally load-bearing components with nominally non-load bearing components exhibiting characteristics that vary as a function of the environmental conditions can significantly affect the monitored structural response. Ignoring these effects may hamper an inference of structural changes from the monitoring data. To address this issue, we adopt a probabilistic model-based framework as a basis for developing digital twins of structural systems that enable a prediction of the structural behavior under varying ambient condition. Within this framework, different types of data obtained from real the structural system can be applied to update the digital twin of the structural system using Bayesian methods and thus enhance predictions of the structural behavior. In this contribution, we implement the framework to develop a digital twin of a simply supported steel beam with an asphalt layer. It is formulated such that it can predict the static response of the beam in function of its temperature. In a climate chamber, the beam was subject to varying temperatures and its static response wass monitored. In addition, tests are performed to determine the temperature-dependent properties of the asphalt material. Bayesian system identification is applied to enhance the predictive capabilities of the digital twin based on the observed data.
Changes in the measured response of structural systems can be an indication of structural damages. However, such changes can also be caused by the effect of varying environmental conditions. To detect, localize and quantify changes or damages in structural systems subject to varying environmental conditions, physics-based models of the structural systems have to be applied which explicitly account for the influence of ambient conditions on the structural behavior. Data obtained from the structural systems should be used to calibrate the models and update predictions. Bayesian system identification is an effective framework for this task. In this paper, we apply this framework to learn the parameters of two competing structural models of a reinforced concrete beam subject to varying temperatures based on static response data. The models describe the behavior of the beam in the uncracked and cracked condition. The data is collected in a series of load tests in a climate chamber. Bayesian model class selection is then applied to infer the most plausible condition of the beam conditional on the available data.
Structural health monitoring (SHM) intends to improve the management of engineering structures. The number of successful SHM projects – especially SHM research projects – is ever growing, yielding added value and more scientific insight into the management of infrastructure asset. With the advent of the data age, the value of accessible data becomes increasingly evident. In SHM, many new data-centric methods are currently being developed at a high pace. A consequent application of research data management (RDM) concepts in SHM projects enables a systematic management of raw and processed data, and thus facilitates the development and application of artificial intelligence (AI) and machine learning (ML) methods to the SHM data. In this contribution, a case study based on an institutional RDM framework is presented. Data and metadata from monitoring the structural health of the Maintalbrücke Gemünden for a period of 16 months are managed with the RDM system BAM Data Store, which makes use of the openBIS data management software. An ML procedure is used to classify the data. Feature engineering, feature training and resulting data are performed and modelled in the RDM system.
Die Infrastruktursysteme der Industriestaaten erfordern heute und in Zukunft ein effizientes Management bei alternder Bausubstanz, steigenden Lasten und gleichbleibend hohem Sicherheitsniveau. Digitale Technologien bieten ein großes Potenzial zur Bewältigung der aktuellen und künftigen Herausforderungen im Infrastrukturmanagement. Im BMBF-geförderten Projekt Bewertung alternder Infrastrukturbauwerke mit digitalen Technologien (AISTEC) wird untersucht, wie unterschiedliche Technologien und deren Verknüpfung gewinnbringend eingesetzt werden können. Am Beispiel der Maintalbrücke Gemünden werden ein sensorbasiertes Bauwerksmonitoring, bildbasierte Inspektion mit durch Kameras ausgestatteten Drohnen (UAS) und die Verknüpfung digitaler Bauwerksmodelle umgesetzt. Die aufgenommenen Bilder dienen u. a. als Grundlage für spätere visuelle Anomaliedetektionen und eine 3D-Rekonstruktion, welche wiederum für die Kalibrierung und Aktualisierung digitaler Tragwerksmodelle genutzt werden. Kontinuierlich erfasste Sensordaten werden ebenfalls zur Kalibrierung und Aktualisierung der Tragwerksmodelle herangezogen. Diese Modelle werden als Grundlage für Anomaliedetektionen und perspektivisch zur Umsetzung von Konzepten der prädiktiven Instandhaltung verwendet. Belastungsfahrten und historische Daten dienen in diesem Beitrag der Validierung von kalibrierten Tragwerksmodellen.
Remediation of Cracks Formed in Grouted Connections of Offshore Energy Structures under Static Loads
(2018)
The future energy demand necessitates the exploration of all potential energy sources both onshore and offshore. Global trend has shifted towards offshore energy, which can be obtained from either carbon intensive or renewable options, hence requiring structures such as rigs, platforms, and monopiles. Most of these structures adopt easily installable construction techniques, where lower foundation need to be connected with the super structure by mean of grouted composite joints. Generally, these composite connections have exterior sleeve, interior pile and infill grout. Being located in remote offshore conditions, connections can experience considerable adverse loading during their lifetimes. Degradations were reported inside similar connections, which were installed in last three decades. Besides, grouting in the offshore sites may often be proven difficult, which eventually leads to reduced capacity of connections in the long run. Thus, repair and rehabilitation of such connections should be planned ahead to minimize operational delays and costs in the future. This study aims at characterizing the nature of crack generation in grouted connections and thereby identifying the potential of repair using suitable repair material. Scaled grouted joints were manufactured using a novel mold, and connections were loaded under static load to visualize the main failure pattern. The failure mechanism and loading capacity are found compatible to previous results from earlier literature. Grouted connection was then repaired using cementitious injectable grout. The effectiveness of the repair system is also discussed.
Grouts have numerous applications in construction industry such as joint sealing, structural repair, and connections in precast elements. They are particularly favoured in rehabilitation of structures due to penetrability and convenience of application. Grouts for repair applications typically require high-performance properties such as rapid strength development and superior shrinkage characteristics. Sometimes industrial by-products referred as supplementary cementitious materials (SCM) are used with neat cement due to their capabilities to provide binding properties at delayed stage. Micro silica, fly ash and metakaolin are such SCMs, those can modify and improve properties of cement products. This study aims at investigating long-term mass loss and linear shrinkage along with long-term compressive and flexural strength for grouts produced from ultrafine cement and SCMs. A series of mixtures were formulated to observe the effect of SCMs on these grout properties. Properties were determined after 365 days of curing at 23oC and 55% relative humidity. The effect of SCMs on the properties are characterised by statistical models. Response surfaces were constructed to quantify these properties in relation to SCMs replacement. The results suggested that shrinkage was reduced by metakaolin, while micro silica and fly ash had positive effects on compressive and flexural strength, respectively.
Repair is an indispensable part of the maintenance of structures over their lifetimes. Structural grouting is a widely used remediation technique for concrete components, trenches, mine subsidence, dam joints, restoration of masonry structures, and geological stabilizations. A structural grout system should be injectable in narrow spaces and hence include ingredients with finer particles. Ultrafine cements are ideal for these type of demanding grouts due to their superior properties compared to that of the less expensive, but coarser ordinary Portland cement (OPC). Supplementary cementitious materials (SCMs) are often used to replace OPC clinker based binder in order to modify certain properties and to reduce costs. The most commonly used SCMs are fly ash (FA), and ground granulated blast furnace slag (GGBS). For various special applications microsilica (MS), and metakaolin (MK) are also used. Identifying the optimum replacement contents of OPC by SCMs are a challenge during the design of such grouts. The aim of this experimental study is to investigate the effect of the selected SCMs (FA, MS and MK) on the slump flow, time of efflux, viscosity, shrinkage, and compressive and flexural strength of ultrafine cement based grouts with constant water-binder ratio and superplasticizer content. The test program was formulated using Box-Behnken design principles. Maximum percentages of replacement with ultrafine cement was 6% by volume of cement for MS and 16% for FA, and MK. The results suggest that most investigated grouts have the potential to be used for structural applications. The appropriate quadratic models are then formulated through statistical tools and presented as response surfaces. The trends indicate that fly ash improves the rheological properties, whereas microsilica and metakaolin positively affect shrinkage and mechanical properties to some extent. Based on the influence of SCMs and priorities among the properties, Decision Matrix Analysis (DMA) is carried out to select the most suitable ones among the SCMs. The analysis suggests that microsilica and fly ash are more suitable as SCMs than metakaolin without affecting the properties.
Grouting is a universal repair and strengthening technique, which is constantly used for structural remediation of concrete components, trenches, mine subsidence, dam joints, restoration of masonry structures, and geological stabilizations. Having an extremely small particle size of only few microns, ultrafine cements are ideal for grouting applications due to their superior permeability and compressive strength properties of the hardened cement paste compared to that of the less-expensive, but coarser ordinary Portland cements. Supplementary cementitious materials (SCMs) are often used to replace ultrafine cement in order to modify certain properties and to reduce costs. The aim of this experimental study is to investigate the effect of three supplementary materials: microsilica (MS), fly ash (FA), and metakaolin (MK) on the workability, and mechanical properties of an ultrafine cement based grout with a constant water-binder ratio and constant superplasticizer content. Maximum percentages of replacement with ultrafine cement were 6% by volume of cement for MS and 16% for FA, and MK. In general, results suggest that the workability is improved by addition of FA, whereas is reduced, when modified with MS and MK. The compressive strength of grout after cement replacement remains comparable to that of pure cement grout. However, there is a tendency of the MS to positively affect the compressive strength opposite to FA, whereas flexural strength is positively affected by FA. Based on the results, it is evident that grouts with Hägerman cone flow more than 500 mm and compressive strength of more than 90 MPa after 28 days can be produced.
Superplasticizer and Shrinkage Reducing Admixture Dosages for Microfine Cement in Grout Systems
(2019)
Grouts have numerous applications including crack repair as maintenance in construction industries. Microfine cements are intensively used for high strength mortar and grout products. They are ideal for injection grouting in structural repair. Such grouts should have suitable rheological properties to be injectable, especially those used in repair and rehabilitation. The use of superplasticizers (SP) in these products is thus becoming increasingly crucial to achieve favorable workability and viscosity properties. A difficulty in such grouts is the plastic shrinkage due to finer particles used. It is thus necessary to determine optimum SP and shrinkage reducing admixture (SRA) dosages for a microfine cement based grout. In this study, a saturation dosage was decided from two Polycarboxylate ether (PCE) based SPs in relation to neat cement using slump flow and rheological parameters. A range of grout mixtures was formulated containing micro silica (MS) and fly ash (FA), and tested for suitable rheological and mechanical parameters. Based on the results, a grout mixture with MS and FA was selected to determine optimum SRA content. According to the results, a SP dosage of 3% by weight of neat cement is sufficient to achieve saturation. The grout material including MS and FA can produce comparable properties to neat cement grout. MS is found to improve compressive strength within the range considered, whereas a higher FA content provides favourable rheological properties. Finally, a SRA dosage of 4%, which could reduce the shrinkage by about 43% after 28d days, is determined for the grout system.
In this contribution, we consider two applications in which probabilistic approaches can potentially complement or enhance the design and assessment of offshore wind turbine foundations. First, we illustrate in a numerical example that probabilistic modelling can be helpful in dealing with chang-es in turbine locations during the planning phase of an offshore wind farm. In this case, spatial probabilistic modelling of the ground conditions enables (a) an inference of the soil properties at the modified turbine location from field data collected at different locations across an offshore wind farm site and (b) an optimisation of further site investigations. Second, we discuss the uncer-tainties and risks associated with the installation of large diameter monopiles in soils with hetero-geneities such as strong layers and/or embedded boulders. Subsequently, we present a concept for modelling, understanding, and managing these risks based on a probabilistic model of the subgrade conditions, monopile, and subgrade-pile-interaction.
Die Anwendung von Leichtbauprinzipien im Stahlbau, wie z.B. die Verwendung von aufgelösten Tragstrukturen, sog. Jackets-Fundamenten, bietet ein großes Potential zur Reduzierung des Ressourcenverbrauchs, insbesondere im Hinblick auf die benötigte Stahlmenge.
In diesem Vortrag zeigen wir die Potenziale einer vollständigen Digitalisierung der schweißtechnischen Fertigungs- und Prüfkette auf, um eine vollautomatische Fertigung sowie Qualitätsprüfung von Rohrknoten als Schlüsselelement von Jackets-Fundamenten zu ermöglichen. Darüber hinaus wird der Zusammenhang zwischen der Geometrie der Nahtform und der resultierenden Ermüdungsfestigkeit durch numerische Methoden unter Einbeziehung bionischer Prinzipien bewertet. Es wird gezeigt, dass Hohlprofilknoten vollautomatisch unter Berücksichtigung von Geometrietoleranzen geschweißt werden können. Darüber hinaus konnte die Nahtform gemäß den numerischen Modellen hergestellt werden, was ein großes Potenzial für eine verlängerte Lebensdauer bietet. Anschließend werden die Verbesserungen bei der Ressourceneffizienz und die Reduzierung der Kohlendioxidemissionen durch eine Lebenszyklusanalyse bewertet.
Innovative Design- und Fertigungsstrategien zur Steigerung der Leichtbaupotenziale im Stahlbau
(2022)
Ziel des Verbundvorhabens „SmartWeld“ ist es, für die schweißtechnische Fertigung von Stahlbaustrukturen exemplarisch am Beispiel von Hohlprofilknoten, welche als designrelevante Elemente von Gründungsstrukturen für Offshore-Windenergieanlagen (OWEA) einsetzbar sind, die Möglichkeiten des Leichtbaus unter konsequenter Digitalisierung der Fertigungskette aufzuzeigen, um einerseits die Ressourceneffizienz zu forcieren und gleichzeitig wettbewerbsfähige Fertigungsstrategien aufzuzeigen.
Innerhalb von „SmartWeld“ werden daher die Möglichkeiten einer wirtschaftlichen Fertigung von Leichtbau-Gründungsstrukturen am Beispiel aufgelöster Tragstrukturen (Jackets) aufgezeigt. Eine lastgerechte Auslegung der Schweißverbindungen nach bionischen Prinzipien ermöglicht, weitere Einsparpotenziale an Ressourcen bei gleichzeitiger Erhöhung der Lebensdauer zu erschließen.
Die Ausnutzung konstruktiver Prinzipien des Leichtbaus zur Erzeugung innovativer und ressourcenschonender Produkte erfordert den Einsatz digitaler Werkzeuge in der Designphase, der virtuellen Absicherung, der Fertigung und Qualitätsüberwachung sowie nachgelagerten Bauteilprüfung zur Abbildung der Nutzungsphase. Im Rahmen der Arbeiten wird daher der gesamte Produktentstehungs- und Prüfprozess betrachtet. Dies beinhaltet das Design im Kontext des konstruktiven Leichtbaus, den schweißtechnischen Fertigungsprozess, die Bauteilprüfung sowie den Transfer der Ergebnisse in die Industrie durch serientaugliche Demonstratoren. Der Fokus der Arbeiten ist, die Fertigung auch im Umfeld eines für großskalige Stahlstrukturen üblichen hohen Individualisierungsgrades schweißtechnisch zu automatisieren und das Leichtbaupotenzial gezielt umzusetzen. Die Vorgaben aus der Designphase hinsichtlich einer lastgerechten Gestaltung bzw. Implementierung bionischer Ansätze können so gezielt durch einen adaptiven, automatisierten Schweißprozess eingestellt werden. Dies führt zu einer Erhöhung der Ermüdungs¬festigkeit und damit Produktlebensdauer, wodurch die Strukturen dünnwandiger ausgeführt und Ressourcen sowie CO2 eingespart werden können.
Innovative Design- und Fertigungsstrategien zur Steigerung der Leichtbaupotenziale im Stahlbau
(2022)
Ziel des Verbundvorhabens „SmartWeld“ ist es, für die schweißtechnische Fertigung von Stahlbaustrukturen exemplarisch am Beispiel von Hohlprofilknoten, welche als designrelevante Elemente von Gründungsstrukturen für Offshore-Windenergieanlagen (OWEA) einsetzbar sind, die Möglichkeiten des Leichtbaus unter konsequenter Digitalisierung der Fertigungskette aufzuzeigen, um einerseits die Ressourceneffizienz zu forcieren und gleichzeitig wettbewerbsfähige Fertigungsstrategien aufzuzeigen.
Innerhalb von „SmartWeld“ werden daher die Möglichkeiten einer wirtschaftlichen Fertigung von Leichtbau-Gründungsstrukturen am Beispiel aufgelöster Tragstrukturen (Jackets) aufgezeigt. Eine lastgerechte Auslegung der Schweißverbindungen nach bionischen Prinzipien ermöglicht, weitere Einsparpotenziale an Ressourcen bei gleichzeitiger Erhöhung der Lebensdauer zu erschließen.
Die Ausnutzung konstruktiver Prinzipien des Leichtbaus zur Erzeugung innovativer und ressourcenschonender Produkte erfordert den Einsatz digitaler Werkzeuge in der Designphase, der virtuellen Absicherung, der Fertigung und Qualitätsüberwachung sowie nachgelagerten Bauteilprüfung zur Abbildung der Nutzungsphase. Im Rahmen der Arbeiten wird daher der gesamte Produktentstehungs- und Prüfprozess betrachtet. Dies beinhaltet das Design im Kontext des konstruktiven Leichtbaus, den schweißtechnischen Fertigungsprozess, die Bauteilprüfung sowie den Transfer der Ergebnisse in die Industrie durch serientaugliche Demonstratoren. Der Fokus der Arbeiten ist, die Fertigung auch im Umfeld eines für großskalige Stahlstrukturen üblichen hohen Individualisierungsgrades schweißtechnisch zu automatisieren und das Leichtbaupotenzial gezielt umzusetzen. Die Vorgaben aus der Designphase hinsichtlich einer lastgerechten Gestaltung bzw. Implementierung bionischer Ansätze können so gezielt durch einen adaptiven, automatisierten Schweißprozess eingestellt werden. Dies führt zu einer Erhöhung der Ermüdungs¬festigkeit und damit Produktlebensdauer, wodurch die Strukturen dünnwandiger ausgeführt und Ressourcen sowie CO2 eingespart werden können.
Innovative Design- und Fertigungsstrategien zur Steigerung der Leichtbaupotenziale im Stahlbau
(2022)
Offshore wind energy plays an important role for the desired transition towards a carbon dioxide free industry within the next decades. However, the grounding of the offshore wind plants governs the overall installation process besides bureaucratic bottlenecks.
The application of lightweight principles in steel construction, e.g. the usage dissolved load-bearing structures, so called Jackets foundations, offer great potential in reducing the resource consumption, especially with respect to the needed amount of steel.
In this context this presentation focuses on a fully digitalization of the welding manufacturing and as well as testing chain to enable a fully automated manufacturing as well as quality assessment of tubular nodes as key element of Jackets foundation structures. Furthermore, the relationship between the seam shape geometry and resulting fatigue strength is evaluated by numerical methods incorporating bionic principles. It is shown that tubular nodes can be welded fully automatically taking geometry tolerances into account. Moreover, the seam shape could be manufactured as requested by the numerical models which offers great potential for an extended lifetime. Subsequently, the improvements in resource efficiency and reduction of carbon dioxide emissions are evaluated by a life-cycle-assessment.
The response of many geotechnical systems, whose structural behavior depends on shearing effect, is closely related to soil structure interaction phenomenon. Experimentally it is found that the localisation of these effect happens at a narrow soil layer next to the structure. Numerically, this behavior can be modelled through inter-face elements and adequate constitutive models. In this work, a constitutive model in the framework of Gen-eralized Plasticity for sandy soils has been chosen to be adapted for the interface zone. From the direct shear experiments a sandy soil at loose and dense states under different normal pressures is considered. The adapted constitutive model is able to reproduce contraction and dilatation of the soil according to its relative density and it shows a good agreement with the experimental data.
The structural performance of many geotechnical systems (e.g. axially-loaded pile foundations), depends on the shearing resistance at the soil interface, which may govern the load bearing capacity of the foundation. Experimental investigations have shown that this interaction is mainly localised within a narrow shear band next to the structure. Under cyclic loading, a contraction of the soil at the interface may arise (net volume loss), possibly leading to a stress relaxation and thus to a reduction of the load bearing capacity (the so-called friction fatigue). Based on the constitutive similarities between soil continua and interfaces, we propose here the adaption of a Generalized Plasticity model for sandy soils for the numerical analysis of interface problems. In this contribution, the results of an experimental campaign for the parameter calibration of the constitutive model are presented. The tests have been conducted with a ring shear device involving different normal stresses, roughness of the steel plates as well as cyclic loading. The new modelling approach shows promising results and has the additional practical advantage that the interface zone and the soil continuum can both be described with the same constitutive model in general boundary value problems.
The shaft bearing capacity often plays a dominant role for the overall structural behaviour of axially loaded piles in offshore deep foundations. Under cyclic loading, a narrow zone of soil at the pile-soil interface is subject to cyclic shearing solicitations. Thereby, the soil may densify and lead to a decrease of confining stress around the pile due to microphenomena such as particle crushing, migration and rearrangement. This reduction of radial stress has a direct impact on the shaft capacity, potentially leading in extreme cases to pile failure. An adequate interface model is needed in order to model this behaviour numerically. Different authors have proposed models that take typical Interface phenomena in account such as densification, grain breakage, normal pressure effect and roughness. However, as the models become more complex, a great number of material parameters need to be defined and calibrated. This paper proposes the adoption and transformation of an existing soil bulk model (Pastor- Zienkiewicz) into an interface model. To calibrate the new interface model, the results of an experimental campaign with the ring shear device under cyclic loading conditions are here presented. The constitutive model shows a good capability to reproduce typical features of sand behaviour such as cyclic compaction and dilatancy, which in saturated partially-drained conditions may lead to liquefaction and cyclic mobility phenomena.
Global energy consumption will increase in the future necessitating both fossil fuels and renewable energy choices - especially wind energy. Such high energy demand requires installation of offshore energy structures, rigs, platforms and towers, which are susceptible to adverse environmental conditions along with maintenances. Due to their large size and remote locations, cylindrical grouted joints are often adopted between substructure and foundation in these offshore platforms and wind structures such as monopiles. However, these connections are composite structures with exterior sleeve, interior pile and infill mortar. Degradation and settlements were reported inside similar connections, which were installed in last three decades. Besides, grouting in the offshore sites were proven difficult to obtain ideal load bearing capacity. In-situ loading conditions were also found to be affecting the failure mechanism inside such connections. This study aims at characterizing the nature of cracks generated in these grouted connections under both static and cyclic loading. Scaled grouted joints were manufactured using a novel reusable mold, and connections were loaded to failure to visualize the main failure patterns. An assessment between failure under these two types of load is drawn along with comparison to previously available literature.
Grouted connections are intensively used in offshore rigs, platforms as well as jacket and monopile offshore wind turbine structures. Being located in remote offshore conditions, these connections can experience considerable adverse loading during their lifetimes. Degradation was reported inside similar connections, which were installed in the last three decades. Grouting in the offshore sites may often be proven difficult, which eventually leads to reduced load-bearing capacity of connections in the long run. Thus, repair and rehabilitation of such connections should be planned ahead to minimize operational delays and costs. In this study, scaled grouted connections were manufactured using a novel mould, whose integrity were monitored using digital image correlation (DIC). The connections were loaded under static load to visualize the main failure pattern using distributed fibre optic sensors and acoustic emission (AE) analysis. Grouted connections were then repaired using a cementitious injectable grout. The effectiveness of the grout injection was monitored using dye penetration technique. Finally, specimens are reloaded to identify the potential of such repair for grouted connections.