Evaluation and Repair of Wrought Iron and - Purdue e-Pubs ...

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62. LITERATURE SEARCHBefore experimental testing began, an in depth literature review was conducted.This review had several goals which were to obtain an accurate description of, andhistorical background for, wrought iron as it was used as a structural material. Also fromthis review, historical tensile strength data of wrought iron was found, collected andanalyzed. Through out the review, many articles dealing with repairs and rehabilitationsof bridges that consisted of wrought iron members were located and summarized. Uponcompleting the review, a survey was created and distributed with the goal of determiningif any such repair procedures are currently used throughout the country.2.1 Background of Wrought Iron2.1.1 Definition of Wrought IronWrought iron was officially defined by the American Society for TestingMaterials in 1930 as:“A ferrous material aggregated from a solidifying mass of pasty particles ofhighly refined metallic iron, with which, without subsequent fusion, isincorporated in a minutely and uniformly distributed quantity of slag.”Wrought iron is considered to be a material that consists of two main components: highpurityiron and iron silicate. Iron silicate, more commonly known as slag, is a glasslikesubstance that is mechanically intermingled with the iron. The addition of slag occursduring the manufacturing process for the wrought iron
7This manufacturing process is dissimilar to common manufacturing processesbecause in this historic process, the metal is never completely molten. In modernmanufacturing processes of metals, the ore is superheated until it is completely fluid andimpurities rise to the surface and are discarded. During the process for making wroughtiron, the metal exists in a red hot pasty condition and impurities are typically beaten androlled out of the material. This creates many of the characteristic properties of wroughtiron.Structurally wrought iron is fibrous in nature. While in the red hot pastycondition after the iron ore has been heated, slag exists in pockets through out thematerial. When the material is rolled, the slag is “squeezed” out. Rolling causes thepockets of slag to become elongated and dispersed throughout the material. Theseelongated deposits of slag influence the iron so that it exists in fibers along one directionof the material. In some cases there may be more than 250,000 slag threads or fibers perone square inch of area (Mills, 1915). This creates a fibrous material structure that issimilar to some types of wood, as can be seen in the fracture depicted in Figure 2.1.Chemically, wrought iron consists of mostly iron with the addition of someelements. Chemical analysis of wrought iron shows that there is typically less than0.15% carbon found in the material (Tiemann, 1919). Although a similar amount ofcarbon is commonly found in some steels, the other elements comprising wrought ironcreate the difference in the materials. Phosphorous and silicon are typically found inwrought iron and steel, but these elements usually exist in excess than what is typicallyfound in steel. An excess of the element silicon is especially characteristic of wroughtiron since it is the main constituent found in the slag which defines the metal.The consistency and quality of wrought iron is difficult to asses simply becausethe manufacturing process utilized to make historic wrought iron was not capable ofmaking wrought iron entirely structurally homogeneous in nature. Because of these
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 10 and 11: ixLIST OF FIGURESFigurePageFigure 1
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 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
Page 62 and 63: 42specimens were of constant cross
Page 64 and 65: 44Along with rectangular tensile co
Page 66 and 67: 46After the initial test loading wa
Page 68 and 69: 483.6 Fatigue TestingTo develop a b
Page 70 and 71: 50The final specimen category consi
Page 72 and 73: 52This analysis was completed using
Page 74 and 75: 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
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64Figure 3.11 Detail Used in Groove
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66900080007000y = 27.153xR 2 = 0.99
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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
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98Table 4.5 Charpy Impact Test Resu
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100Table 4.7 Comparison of Strain G
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102Figure 4.1 Typical Micrograph of
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104Figure 4.5 Fracture Surface of D
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106Comparison of Tensile Strengthfo
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108Combined Wrought Iron Bar Histor
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110Figure 4.17 Macrograph of Weld u
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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
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126Keating (1984) stated that the s
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128charcoal fire until it is red ho
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130Figure 5.3 Picture of Bottom Cho
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132Figure 5.7 Using Force After Usi
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134Figure 5.11 Reassembling a Pin C
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1366. SUMMARY, CONCLUSIONS AND IMPL
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138rectangular in shape. These eyeb
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140were joined together with a full
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1424. The Charpy impact energy of t
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144connections are unsymmetrical, i
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146LIST OF REFERENCESAASHTO (1998).
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148Hodgkinson, Eaton (1840). Experi
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150Appendix A. Data Collected From
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152Table A.1 Wrought Iron Bar Tensi
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154Table A.1 (continued) Wrought Ir
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156Table A.2 (continued) Wrought Ir
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158Table A.3 Wrought Iron Angle Ten
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160Table A.4 (continued) Summary of
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162Table A.4 (continued) Summary of
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164Table A.5 (continued) Detailed I
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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
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194State 13: Included in original d
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196Figure C.1 Diagrams Showing Loca
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198Figure C.3 Heating of Eyebar fro
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200Figure C.7 Double V Butt Joint u
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202Figure C. 11 Welded Tensile Coup
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204Figure C.15 Tensile Coupon from
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206Figure C.19 Cooling Bath with Su
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208Figure C.23 Side View of Eyebar
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210Figure C.27 Eyebar End Connectio
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212Appendix D. Welding Procedure fo
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214D.2 Filler Weld for Eyebar Conne
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216Figure D.1 Weld Joint Detail Use
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Figure D.5 Completed Weld Before Su
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220Figure D.7 Initial Pass Pattern
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