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ixLIST OF FIGURESFigurePageFigure 1.1 Historic Wrought Iron Bridge Spanning Laughery Creek, Aurora vicinity,Dearborn County, IN (Historic American Buildings Survey/Historic AmericanEngineering Record) ................................................................................................... 5Figure 1.2 Picture Showing Fibrous Nature of Wrought Iron. (Aston, 1949)................... 5Figure 2.1 Fracture Showing Fibrous Nature of Wrought Iron. (Aston, 1949)................ 29Figure 2.2 Cross Section of Pudding Furnace (Johnson, 1928)........................................ 29Figure 2.3 Wrought Iron “Sponge Balls” being transported after firing (Aston, 1949) ... 30Figure 2.4 Front page of Pamphlet from Wrought Iron Bridge Co. Canton OH.............. 30Figure 2.5 Picture of Bessemer Converter (Aston, 1949)................................................. 31Figure 2.6 Drawing of Testing machine at Robert Napier’s Vulcan Foundry Works inGlasgow (Kirkaldy 1962) ......................................................................................... 31Figure 2.7 Tensile Strength of Wrought Iron Bars Tested by Kirkaldy ........................... 32Figure 2.8 Tensile Strength of all Wrought Iron Shapes Tested by Kirkaldy .................. 32Figure 2.9 Percent Elongation of Wrought Iron Bars Tested by Kirkaldy ....................... 33Figure 2.10 Tensile Strength of Wrought Iron Bars Tested by Beardslee........................ 33Figure 2.11 Yield Strength of Wrought Iron Bars Tested by Beardslee........................... 34Figure 2.12 Percent Elongation of Wrought Iron Bars Tested by Beardslee.................... 34Figure 2.13 Tensile Strength of all the Data Combined ................................................... 35Figure 2.14 Tensile Strength of all the Bar Data Combined............................................. 35Figure 2.15 Percent Elongation of all the Bar Data Combined ........................................ 36Figure 2.16 Bar Chart Showing the Number of States with Certain Number of Bridges. 36Figure 3.1 Bell Ford Bridge After Collapse of One Span................................................ 59Figure 3.2 Donated Eyebars 1 thru 3 ............................................................................... 59
xFigurePageFigure 3.3 Donated Eyebars 4 and 5 Along With a Similar Eyebar that Was Straightenedand Used in the Reconstruction of the Bell Ford Bridge.......................................... 60Figure 3.4 Round Diagonal Tensile Rods........................................................................ 60Figure 3.5 Micrograph of Wrought Iron (100 x magnification) ...................................... 61Figure 3.6 Hardness Values for One Sample of Wrought Iron........................................ 61Figure 3.7 Heated Areas in Blue on Eyebar 2 ................................................................. 62Figure 3.8 Piece of Historic Wrought Iron From Eyebar 3 Heated Till it is Cherry Red InColor ......................................................................................................................... 62Figure 3.9 Tensile Coupon Dimensions per ASTM 370 ................................................. 63Figure 3.10 Method used to Mechanically Straighten a Bar ........................................... 63Figure 3.11 Detail Used in Groove Weld Test Specimens ............................................... 64Figure 3.12 Weld Detail after Initial Root Pass on Testing Specimen ............................. 64Figure 3.13 Round Tensile Testing Specimen................................................................. 65Figure 3.14 Specimen in Testing Machine Ready to be tested........................................ 65Figure 3.15 Typical Plot of Stress vs. Strain from Elastic Test....................................... 66Figure 3.16 Typical Plot of Stress vs. Strain from Test to Full Failure........................... 66Figure 3.17 Orientation of Different Charpy Specimens................................................. 67Figure 3.18 Dimensions of Charpy Specimens per ASTM E23...................................... 67Figure 3.19 Charpy Impact Testing Machine ................................................................... 68Figure 3.20 Liquid Bath Setup used for Cooling Charpy Specimens.............................. 68Figure 3.21 Placement of Strain Gages on Eyebar Connections ..................................... 69Figure 3.22 Eyebar Connection After Strain Gages were Applied.................................. 69Figure 3.23 Eyebar Connection in MTS Machine with Added Setup before Testing..... 70Figure 3.24 Plot of Linear Strain Readings from Strain Gages on Eye Connection ........ 70Figure 3.25 Eyebar Connection A After Material Was Removed to Simulate Corrosion 71Figure 3.26 Initial Filler Weld Pass on Eyebar Connection A ........................................ 71Figure 3.27 Eyebar A After Filler Weld was Completed and Before Surface Grinding. 72Figure 3.28 Eyebar B After Material Was Removed to Simulate Worst Case Corrosion72Figure 3.29 Initial Filler Weld Passes on Eyebar Connection B ..................................... 73
Page 1 and 2: Purdue UniversityPurdue e-PubsJTRP
Page 3: 1. Report No. 2. Government Accessi
Page 6 and 7: epairing a bent wrought iron tensio
Page 8 and 9: vPageCHAPTER 3TEST PROCEDURES FOR M
Page 12 and 13: xiFigurePageFigure 3.30 Top View of
Page 14 and 15: xiiiFigurePageFigure 5.12 Typical T
Page 16 and 17: xvAppendix FigurePageFigure D.7 Ini
Page 18 and 19: viiiAppendix TablePageTable A.5 Det
Page 20 and 21: iiiThe authors would also like to t
Page 22 and 23: 2but also what material properties
Page 24 and 25: 4microstructure of the metal. The c
Page 26 and 27: 62. LITERATURE SEARCHBefore experim
Page 28 and 29: 8imperfections, the performance of
Page 30 and 31: 10wrought iron. Adding the slag aft
Page 32 and 33: 12method for manufacturing wrought
Page 34 and 35: 14patents for their process and tra
Page 36 and 37: 16This method of testing of structu
Page 38 and 39: 18plot of this percent elongation d
Page 40 and 41: 20significant variation in the perc
Page 42 and 43: 22The practice of restoring histori
Page 44 and 45: 24Elleby, Wallace W. Sanders, F. Wa
Page 46 and 47: 26From all the surveys that were di
Page 48 and 49: 28Table 2.1 Average Ultimate Streng
Page 50 and 51: 30Figure 2.3 Wrought Iron “Sponge
Page 52 and 53: 32Histogram of Kirkaldy Wrought Iro
Page 54 and 55: 34Percent Occurance in Range - %45.
Page 56 and 57: 3660Combined Wrought Iron BarsTensi
Page 58 and 59: 38The Bell Ford Bridge consisted of
Page 60 and 61:
40Two. These samples were taken fro
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42specimens were of constant cross
Page 64 and 65:
44Along with rectangular tensile co
Page 66 and 67:
46After the initial test loading wa
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483.6 Fatigue TestingTo develop a b
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50The final specimen category consi
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52This analysis was completed using
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54After the initial test was comple
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56completed, but before the surface
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58readings, load cell readings and
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60Figure 3.3 Donated Eyebars 4 and
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62Figure 3.7 Heated Areas in Blue o
Page 84 and 85:
64Figure 3.11 Detail Used in Groove
Page 86 and 87:
66900080007000y = 27.153xR 2 = 0.99
Page 88 and 89:
68Figure 3.19 Charpy Impact Testing
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70Figure 3.23 Eyebar Connection in
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72Figure 3.27 Eyebar A After Filler
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74Figure 3.31 Side View of Finished
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76Figure 3.35 Front View of Eyebar
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78strength from the existence of pe
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80The carbon content present in the
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82value may not be very accurate bu
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84strengths was found to be 29,940
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86wrought iron bars were investigat
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88stresses are induced. These perma
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90toughness the material. The test
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92From the finite element analysis,
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94Table 4.1 Chemical Analysis of Ey
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96Table 4.3 Tensile Coupon Test Res
Page 118 and 119:
98Table 4.5 Charpy Impact Test Resu
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100Table 4.7 Comparison of Strain G
Page 122 and 123:
102Figure 4.1 Typical Micrograph of
Page 124 and 125:
104Figure 4.5 Fracture Surface of D
Page 126 and 127:
106Comparison of Tensile Strengthfo
Page 128 and 129:
108Combined Wrought Iron Bar Histor
Page 130 and 131:
110Figure 4.17 Macrograph of Weld u
Page 132 and 133:
112Figure 4.21 Cleavage Fracture of
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Figure 4.25 Elongation of Hole in E
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116signs on or near the bridge that
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118testing of historic wrought iron
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120so that they would act in symmet
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122The reasons for the differences
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124The second corrosion pattern mod
Page 146 and 147:
126Keating (1984) stated that the s
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128charcoal fire until it is red ho
Page 150 and 151:
130Figure 5.3 Picture of Bottom Cho
Page 152 and 153:
132Figure 5.7 Using Force After Usi
Page 154 and 155:
134Figure 5.11 Reassembling a Pin C
Page 156 and 157:
1366. SUMMARY, CONCLUSIONS AND IMPL
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138rectangular in shape. These eyeb
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140were joined together with a full
Page 162 and 163:
1424. The Charpy impact energy of t
Page 164 and 165:
144connections are unsymmetrical, i
Page 166 and 167:
146LIST OF REFERENCESAASHTO (1998).
Page 168 and 169:
148Hodgkinson, Eaton (1840). Experi
Page 170 and 171:
150Appendix A. Data Collected From
Page 172 and 173:
152Table A.1 Wrought Iron Bar Tensi
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154Table A.1 (continued) Wrought Ir
Page 176 and 177:
156Table A.2 (continued) Wrought Ir
Page 178 and 179:
158Table A.3 Wrought Iron Angle Ten
Page 180 and 181:
160Table A.4 (continued) Summary of
Page 182 and 183:
162Table A.4 (continued) Summary of
Page 184 and 185:
164Table A.5 (continued) Detailed I
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Page 188 and 189:
Page 190 and 191:
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Page 194 and 195:
Page 196 and 197:
Page 198 and 199:
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Page 202 and 203:
Page 204 and 205:
184Table A.7 Tensile Strength Data
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186Table B.1 Example Historic Wroug
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188DepartmentofTransportationIf you
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190CountyIf your organizationdoes m
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192County 16: County bridge inspect
Page 214 and 215:
194State 13: Included in original d
Page 216 and 217:
196Figure C.1 Diagrams Showing Loca
Page 218 and 219:
198Figure C.3 Heating of Eyebar fro
Page 220 and 221:
200Figure C.7 Double V Butt Joint u
Page 222 and 223:
202Figure C. 11 Welded Tensile Coup
Page 224 and 225:
204Figure C.15 Tensile Coupon from
Page 226 and 227:
206Figure C.19 Cooling Bath with Su
Page 228 and 229:
208Figure C.23 Side View of Eyebar
Page 230 and 231:
210Figure C.27 Eyebar End Connectio
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212Appendix D. Welding Procedure fo
Page 234 and 235:
214D.2 Filler Weld for Eyebar Conne
Page 236 and 237:
216Figure D.1 Weld Joint Detail Use
Page 238 and 239:
Figure D.5 Completed Weld Before Su
Page 240 and 241:
220Figure D.7 Initial Pass Pattern
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