Faculty of Engineering - Cairo Fall ٢٠٢٢

University STR654

STR654:
INSPECTION, MAINTENANCE and
REPAIR of STEEL STRUCTURES
Lecture 10, December 6, 2022

Sherif A. Mourad

Professor of Steel Structures and Bridges

Faculty of Engineering,
Cairo University

Introduction

Learning From Failure: Case Studies

Strengthening Steel Elements

Strengthening Calculations

Strengthening by Heat Treatment

Strengthening with FRP

Sherif A. Mourad - Lecture 10 ١

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Why Strengthen?
Inadequate design.

(Design loads – modeling - …)

Heavier live loads.

(Changes in usage of building – Upgrading - …)

Local deterioration.
(aging – lack of maintenance - …)

Introduction
Assessing Building Condition:
Visual Inspection.

Tests.

Simple analysis methods to examine the system.

Detailed assessment.

Sherif A. Mourad - Lecture 10 ٢

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Condition Rating of Structure:
Failed Condition: the structure must be demolished and
re-built.

Critical Condition: the structure requires major

strengthening. Closed till corrective action is taken.

Serious Condition: the structure requires strengthening.

Fair Condition: the structure requires regular

maintenance.

Sound Condition.

Introduction

Performance of building material, building component or

structure in time:
(a) no corrective or preventive maintenance required, no
damage
(b) corrective maintenance was necessary, damage.

Sherif A. Mourad - Lecture 10 ٣

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Strengthen or Replace?
Age of the structure.

Quality of material.

Fatigue effect on operation.

Estimated cost.

Added length of life.

Possible future increase in load.

Introduction
Strengthen or Replace?
Typically, strengthening is undertaken only to
improve certain weak parts, not the entire member.

If it is found that the entire member (the entire span

of a bridge, for example), it may be more
economical to replace the member, rather than
strengthen it.

Sherif A. Mourad - Lecture 10 ٤

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Strengthen or Replace?

Strengthen or Replace?

Sherif A. Mourad - Lecture 10 ٥

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction

Steps Taken Before Implementation of

Strengthening:

Physical condition.

Evaluation of stresses.

Effect of eccentricity.

Use of welding.

Introduction
Physical Condition
Physical condition shall be determined by a
detailed inspection.
Establish the type of steel and its physical
and chemical properties by examining
original documents and/or taking specimens
for testing.
Carry out load test to check actual stresses,
deflections, and vibrations.

Sherif A. Mourad - Lecture 10 ٦

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Physical Condition
Table A. This table is a guide that lists the most probable
yield strength for W shapes. Actual yield strength of
existing framing members should be defined from
existing drawings or verified by testing.

2.11 t/cm2

2.54 t/cm2

Introduction
Evaluation of Stresses
Allowable stresses of the added materials
under the load for which they are
strengthened shall conform to the Egyptian
Code.

Sherif A. Mourad - Lecture 10 ٧

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Evaluation of Stresses
New material shall be considered effective in
carrying additional (live) load only, unless
dead load stresses are removed temporarily
from the members.

The stresses of the original section shall be

checked under dead load and any additional
live loads.

Introduction
Evaluation of Stresses
Members shall be investigated for any loss
of strength resulting from the temporary
removal of rivets, cover plates or any other
parts.

Sherif A. Mourad - Lecture 10 ٨

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Evaluation of Stresses
Strengthening shall not be confined to main
members only, but shall include bracing,
lacing, battens, …

Introduction
Evaluation of Stresses

Height

1
Span

Current Condition: The current Loads case

Fo = No/Ao

Sherif A. Mourad - Lecture 10 ٩

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Evaluation of Stresses

Height

1
Span

During Repair: Decrease applied loads

Fi = (No – N1)/Ao = Ni/Ao

Introduction
Evaluation of Stresses

Height

1
Span

Final Condition:
Ff = Ni/Ao + (Nf – Ni) / Af

Ff = Nf / Af Only true in case of complete shoring.

Sherif A. Mourad - Lecture 10 ١٠

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction

Introduction
Eccentricity
The added material shall preferably be
applied so as to obtain a symmetric section.

If a symmetric section cannot be achieved,

the eccentricity of the member shall be taken
into consideration in the stress analysis.

Added plates
at two sides

Sherif A. Mourad - Lecture 10 ١١

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Introduction
Welding
Electric arc welding may be used subject to
approval.

Welds and rivets shall not be assumed to

work together.

Welding shall be in accordance with the

Egyptian Code.

Introduction
When welds are added to existing rivets:
Welds shall be designed to transmit the entire
stresses, except where the original member
shall sustain the entire DL, then the welds
shall be designed to carry only the LL.

When a few of the rivets are loose or

defective, HSB may be used to carry DL
provided they are installed prior to welding.

Sherif A. Mourad - Lecture 10 ١٢

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Main Beams

Main Beams
Flanges and web.

Stiffeners.

Initial tension.

Effective span.

Wind bracing.

Increasing the number of girders.

Substitution.

Sherif A. Mourad - Lecture 10 ١٣

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Flanges & Web

Flange section may be increased by adding cover plates
or by replacing the existing cover plate by a new one.

Flanges & Web

If the exposed surface of old cover plates is rough or
uneven from the effect of corrosion, they shall be
discarded and new plates provided.

If more than one plate shall be replaced, it is better to

replace them with a single plate with adequate size.

Sherif A. Mourad - Lecture 10 ١٤

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Flanges & Web

Cover plates added to plate girders without existing
cover plates shall be full length, and shall be connected
with rivets, HSB, or continuous fillet weld (if material is
weldable).

Flanges & Web

If it is difficult or expensive to remove the R.C. floor on
top of beams, the flange section may be increased by adding
full-length angles or plates just below the flange angles.

Bottom flanges may be similarly reinforced to keep

symmetry.

Sherif A. Mourad - Lecture 10 ١٥

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Flanges & Web

Flanges & Web

Sherif A. Mourad - Lecture 10 ١٦

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Flanges & Web

Flanges & Web

If the web cannot carry the loads, a bolted reinforcing
web should be introduced.

Sherif A. Mourad - Lecture 10 ١٧

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Stiffeners
Bearing stiffeners may be strengthened by adding
angles or plates, grinding the new plates so that they fit
tightly, or by welding them to the flanges.

Intermediate stiffeners may be added by riveting, HSB,

or welding. Ensure that they are not welded to the tension
flange.

Stiffeners

Sherif A. Mourad - Lecture 10 ١٨

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Initial Tension
Initial tension may be introduced to a new cover
plate by:

Welding one end of the flange angles.

Heating the plate till it expands to a predetermined

length.

Initial Tension
Initial tension may be introduced to a new cover
plate by:

Weld the other end of the plate and allow it to cool.

Complete welding of the plate in the longitudinal

direction.

Sherif A. Mourad - Lecture 10 ١٩

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Effective Span
The effective span of the main beams may be
reduced by:

Moving the bearings nearer to the edge of the

support (provided the seat is wide enough, and that
it is checked for the new eccentricity).

Introducing new knee bracing (provided the

columns / abutment can sustain the lateral
component.

Effective Span

Adding columns or girders Adding bracing

Sherif A. Mourad - Lecture 10 ٢٠

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Number of Main Girders

Strengthening may be done by doubling the main
girders (reducing the spacing by one-half) and
providing the necessary lateral bracing for the new
beams.

Spacing should consider allowing for inspection,

maintenance, and painting of the interior surface of
the beams.

Connections

Sherif A. Mourad - Lecture 10 ٢١

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Main Beams
Beam-to-beam connections.

Lateral bracing connections.

Riveted joints.

Stringer Bracket

Adding brackets

Adding weld lines

Sherif A. Mourad - Lecture 10 ٢٢

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Stringer Bracket

Adding seat angle

Remove existing
rivets and add HSB

Truss Systems

Sherif A. Mourad - Lecture 10 ٢٣

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Truss Systems
Addition of new trusses:
New truss should be of stiffness comparable to
the old trusses.

New truss should be joined with the bracing

system to ensure uniform deflection.

Truss Systems
Auxiliary Support System:
New intermediate supports may be introduced
to shorten the span.

A complete re-analysis is necessary as straining

actions may reverse direction.

Members having insufficient capacity shall be

strengthened prior to installation of the new
supports.

Sherif A. Mourad - Lecture 10 ٢٤

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Truss Systems
Additional Chords:
Convert the existing truss by adding new
members to increase the depth.

For the new system to be fully effective for DL

and LL, initial stresses must be provided into
the new chord.

Truss Systems
Additional Support:

Sherif A. Mourad - Lecture 10 ٢٥

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Truss Systems
Additional Chords:

Truss Systems
Inserting Additional Members:

Sherif A. Mourad - Lecture 10 ٢٦

Faculty of Engineering - Cairo Fall ٢٠٢٢
University STR654

Truss Systems
Truss Connections:

Sherif A. Mourad - Lecture 10 ٢٧