Brent Spence Fracture Critical 2012 Inspection Report
Brent Spence Fracture Critical 2012 Inspection Report
DearMr.Rogers,
Michael Baker, Jr. (Baker) has completed the NBI and Fracture Critical inspection of the Brent Spence Bridge (I75
and I71) over the Ohio River in Kenton County, KY. The inspection included the 3 spans of the double deck
cantilevered through truss (453 830.5 453). Inspection activities began on November 5, 2012 and were
completedonNovember10,2012utilizing7bridgeinspectors.Bakercompletedthefieldinspectioninaccordance
withtheScopeofWorkforthereferencedproject.
DESCRIPTIONOFFIELDINSPECTION
Thetypeofinspectionforthisprojectwasafracturecritical,NBI,andelementlevelinspectionincluding:
Arms length inspection of all Fracture Critical members and Fatigue sensitive details including category E,
EandFdetailsinthegirdersandfloorbeams.
Armslengthinspectionofsignificantproblemsdiscoveredduringpriorinspections,
Armslengthinspectionoffloorbeamsupportconnections,
Floorsystemelementsunderdeckcontrolandexpansionjointswereobservedfromeachend.Ifevidence
of deterioration, abnormal sounding or misalignment of members was observed, and arms length
inspectionofthoseelementswasperformed.
Awalkoverinspectionofthedeck,
Armslengthinspectionofbearingassemblies
Armslengthinspectionofinteriorandexteriorofsteelpiercaps.
NDE including Magnetic Particle or Dye Penetrant testing was performed where new cracks were visually
foundorsuspectedand wherecracksweresuspectedtohavegrowntoverifythecrackanddetermineits
limits.Crackterminiweremarkedinthefieldwithdate.
Inspection of all other elements at a distance deemed practical, without requiring climbing or specialized
equipment,
DatagatheringandconditionreportingforbothNBIandPontiselementlevelinspectionreporting.
INSPECTIONINTRODUCTION
The floorbeams supporting the upper roadway were inspected using (2) bucket trucks. The remaining truss
elements were inspected utilizing rope access methods. Traffic was maintained in accordance with the Kentucky
Department of Highways(KDOH) Standard Drawing TTC115, Lane Closure MultiLane Highway Case I. The bridge
was inspected utilizing single lane closures. Lane closures were allowed between 10pm to 6am. Two (2) law
enforcement officers were utilized with interstate lane closures. Traffic control and inspection equipment were
providedbyPittsburghRigging.Amannedsafetyboatwasusedwheneverinspectorswereworkingoverwater.
Typicaltransversecrackingwithlightefflorescence onlowerroadwaydeck.
Typicaltransverseandlongitudinalcracksonupperroadwaysurface.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
Span3atFB3Typicalspallonbottomoflowerdeck, adjacenttojoint.
Span1atFB6Crackingwithefflorescenceonbottomofupperdeck, adjacenttojoint.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
Span3atFB0Crackingwithefflorescenceonbottomofupperdeck, adjacenttofinger
joint.
Span2atFB23Undersideviewoftypicaljointrepaironupperdeck joint.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI58.3Joints,58.4Drainsand58.5ExpansionDevices
2. The upper deck joints have been repaired since the previous inspection and are in overall satisfactory
condition.Lowerdeckjointsareinoverallpoorcondition.Primarydeficienciestolowerdeckjointsoccur
on bottom of the deck (see 58.1) and leakage. Drains are in poor condition. The majority of the deck
drain inlets are full of debris and downspouts exhibit corrosion and varying levels of section loss. Finger
expansionjoints,withtroughs,arefullofdebris.Fingerjointsappeartobestructurallysound.
Span1,PP0Fingerexpansionjointupto5/8
verticaloffsetbetweenfingerswasnoted.
Typicalminorspalladjacenttodeckjoint.
Span1,PP0drainpipesectionwhichisheavilycorroded. Typicalcloggeddrain.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI58.7Railings
3. Theconcreterailisinoverallsatisfactorycondition.Theconcretebarriershaveverticalcracksatregular
intervals.Atisolatedlocations,concretehasspalledoffthefaceortopofbarrier,exposingreinforcement.
Severalutility/lightingjunctionboxcoveredwereeitherdamagedormissing.
Span2:TypicalParapetCracking Span2, betweenPP19 20Spallwithexposed
reinforcementontopofparapet
SpalledconcretefromapparentimpactdamageatPP0,
upperdeck,downstreamside.
Typicalcrackedjunctionboxplateonlowerdeck.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI58.8Lighting
4. Roadwaylightingisinoverallsatisfactorycondition.Navigationlightingwasobservedworking.
SUPERSTRUCTUREOverallConditionRating=Satisfactory(6)
NBI59.1Stringers,Girders,Beams
5. Thestringersaregenerallyinsatisfactorycondition.Lightcorrosionwasnotedatthestringerendsunder
thedeckjointsandfingerjointlocations.
CracksinthetopflangefilletweldofthesecondarydiaphragmsatUD0wereobservedat(1)Str2,WFat
4.125,(2)Str2,EFat6.75,(3)Str3,WFat6,(4)Str5,EFat7,(5)Str5,WFat8,(6)Str6,EFat3.25,
(7)Str7,EFat5.5and(8)Str7,WFat4.5.
Brokengreenlensfornavigationlighting,DSside.Lightbulb
wasworking.
UD0,Str.7,E.Side5crackinT/flngfilletweld. UD0,Str.2,E.Side 6crackinT/flngfilletweld.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI59.2FloorBeams
6. Thefloorbeamswereobservedinoverallfaircondition.Theprimarydeficienciesnotedwerecracksatthe
floorbeamconnectiontothetruss.Ofthefourteentotallocations,twolocationswereobservedattheend
ofthefloorbeamtopflangeangleattheconnectiontothetruss,elevenlocationswerenotedattheendof
thefloorbeamintheTconnectionattheconnectiontothetrussandone5/8crackoriginatingatrivet
holetoedgeoffillplateofFB16,UD,DS(seeAppendixfortable).
Thefloorbeamsalsoexhibitminorsectionlossandsurfacerustthroughoutthebridge.Underthe
expansionjoints,thereismoderatecorrosionanddebrisontopofthefloorbeams.Thebuiltupbox
girderfloorbeamsatUD17andUD17exhibitminortomoderatecorrosionwithsectionlossofthetop
flangeandrivetheads.
TypicalTconnectionatfloorbeamconnectiontotruss. TypicalcrackinTconnectioncloseup
Typicalcrackinfloorbeamatconnectiontotruss closeup. FB16,UD,DS 5/8crackinfillplate
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI59.3TrussMainMembers
7. Overall,themaintrussmembersareinsatisfactorycondition.Thefollowingdeficiencieswereobserved
a. Thereispackrustoccurringatthelowerchord,particularlyonthespliceplates,fillerplates,andcover
plates.Thereisalsopackrustalongtheedgesofthelowerchord.Thispackrustiscausingtheedgeofthe
platetocurlup.Minortomoderatesectionlossisoccurringontheundersideofthelowerchord,
particularlyintheareaofthecoverplatesandspliceplates.
b. Corrosionisbeginningtoreactivate,primarilyatthepanelpoints.
c. Theupperchordmembersareinoverallgoodcondition.Theminordeficienciesobservedincludes(1)
surfacerustandminorpackrustalongtheedgesofgussetplates,(2)minordebrisandsurfacerustinsideof
thetopchordaroundtheconnectionboltsforthetopchordsplices,(3)minorpackrustalongtheedgesof
thetopchordmember,and(4)lightsurfacecorrosioniswidespreadalongthetopsurfacesofthetruss
members.
d. Thetopguideplatesontheupperchordpinsarefractured.ThesearelocatedatL17DSandUS,andL17
DS.Thereisfrettingcorrosionatthepinandsurfacerust.
e. Theinboardandoutboardgussetplatesaregenerallyinsatisfactorytogoodcondition.Thereissurfacerust
andflakingpaintonthegussetplates,andpackrustaroundtheedgesoftheplates.Thereissectionloss,
upto1/8,atsomelocations.SeeAppendixforGussetPlateEvaluationTable.
UD17and17BoxGrdrFloorBeamTypical
insideviewlookingtowardsmidspanoffloor
beam.
UD17and17BoxGirderFloor Beam Lookingupatinsideviewoft/flange
endattrussnotelighttomoderatecorrosiononbottomsideoftop
flange.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
Typicalpackrustalongedgesoffillerplatesatgussets. Typicalpackrustalongedgeoflowerchord.
Typicalinsideviewatpanelpoint.Notetheminor
activecorrosion.
Typicalinsideviewoflowerchordlookingtowardsmidpanel.
PP4,USTruss,InboardGussetSectionlossat1/8max.wasobserved(seeredarrow)ongusset.Seeappendixfortable.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI59.3aTrussBracing,Portals
1. Thebracingandportalmembersaregenerallyinsatisfactorycondition.Lightsurfacerustwasnoted
throughoutthebridge.Thereare(2)looseboltsatthebottomofthelateralbracingconnectingU22,DS.
NBI59.3bTrussInspectionWalk
2. Theinspectionwalkisinoverallsatisfactorycondition.Themaindeficiencynotedwasapairoffractured
connectionanglesatFB16forFB17FB16.Theendoftheinspectionwalkissittingonlowerlateralgusset
plate.
U17U18nearPP17,USTruss,InboardSide Fracturedguideplate(seeredarrow). DSTrussissimilar.
FB17FB16Fracturedconnectionangles(seeredarrow).Inspectionwalkwayendissittingonlowerlateralgussetplate.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
NBI59.4BearingDevices
3. Themaintrussbearingdevicesaregenerallyinsatisfactorycondition.Thestringerbearingsbelowjoints
inboththeupperandlowerdecksaregenerallyinfairconditionwithlighttomoderatepackrustand
minortomoderatesectionloss.
Typicalstringerbearingatupperfingerjoint. Typicalstringerbearingatupperdeckjoint.
Typicaltrussexpansionbearing. TypicalstringerbearingatFB17.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
PAINTCONDITIONOverallConditionRating=Fair(5)
4. Thepaintconditionisinoverallfaircondition.
a. Corrosionisactiveinlocationsexposedtodeckrunoff.
b. Lightsurfacerustwasobservedonthetopsofseveraltrussmembers.
c. Thefloorbeamsandstringerssupportingtheupperroadwayareinfairtopoorconditiondueto
apparentenvironmentalexposurefromvehicleexhaustfumes.
Typicalpoorpaintconditiononupperroadwayfloorbeams. Typicallightsurfacerustonlowerchord.
Typicallightsurfacerustontopoftrussmembers. Typicalwidespread surfacerustontrussmembersinSpan2.
2012 NBI and Fracture Critical Inspection
Brent Spence Bridge over the Ohio River
SUBSTRUCTUREOverallConditionRating=Satisfactory(6)
NBI60.2Piers
12. Overall,thepiersareinsatisfactorycondition.MinorcrackswithminorspallswereobservedforPiersI,
II,andIII.PierIVexhibitsheavymapcrackinganddelaminationalongbottomofpiercapandthefull
heightoftheupstreamcolumn,westface.
PierII,USFaceoverallview.
RiverPierIII,DSFace.
North 23/4",15/8",1/8"
South 25/8",11/4",1/2",1/8"
0 US South CracksinWeb 11/2"
1 US North CracksinTconnection 11/2"
14' DS South CrackinTconnection 11/4"
North 11/4"
South 1"
North 1"
South 17/8"
North 13/16"
South 15/8"
North 13/4"
South 15/8"
South 5/8"
North 1/4"
South 13/16"
North 1"
CrackinTconnection 11/2"
CracksinWeb 13/8"
South CrackinTconnection 23/8",7/8"
North 2"
South 2"
1' DS South CracksinTconnection 1"
Brent Spence Bridge (I-71) over the Ohio River
059B00046N: Summary of Floorbeam Cracks - Lower Roadway
Span
Panel
Point
Truss
Side
Flrbm.
Face
LocationDescription 2012Length
0 DS CracksinTconnection
CrackinTconnection
1
2
17 DS
16 US
16 DS
16' US
3
CrackinTconnection
16' DS CrackinTconnection
CrackinTconnection
CrackinTconnection
17 US CrackinTconnection
0' US CrackinTconnection
0' DS
North
InboardPlate OutboardPlate CS InboardPlate OutboardPlate CS
L0 5/8",1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L1 1/2" Trad.Tools Trad.Tools 3 UT UT 4
L2 5/8" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L3 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L4 5/8" Trad.Tools Trad.Tools 4 UT UT 4
L5 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 3
L6 11/16" Trad.Tools Trad.Tools 4 UT UT 4
L7 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L8 5/8",11/16" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L9 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
L10 3/4" Trad.Tools Trad.Tools 4 UT Trad.Tools 4
L11 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 3
L12 3/4",3/4",5/8" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L13 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
L14 5/8" Trad.Tools Trad.Tools 4 UT UT 4
L15 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
L16 5/8" Trad.Tools Trad.Tools 4 UT UT 4
L17 3/4" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L18 1/2" Trad.Tools Trad.Tools 4 UT UT 4
L19 3/4" Trad.Tools Trad.Tools 4 UT Trad.Tools 4
L20 1/2" Trad.Tools Trad.Tools 4 Trad.Tools UT 4
L21 5/8" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L22 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L23 5/8" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L22' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools UT 4
L21' 5/8" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L20' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L19' 3/4" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L18' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L17' 3/4" Trad.Tools Trad.Tools 4 UT UT 4
L16' 5/8",11/16" Trad.Tools Trad.Tools 4 UT UT 4
L15' 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
L14' 5/8" Trad.Tools Trad.Tools 4 Trad.Tools UT 4
L13' 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
L12' 5/8",3/4" Trad.Tools Trad.Tools 4 UT Trad.Tools 4
L11' 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 3
L10' 3/4" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 3
L9' 1/2" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
L8' 11/16" Trad.Tools Trad.Tools 4 UT Trad.Tools 4
L7' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L6' 11/16" Trad.Tools Trad.Tools 4 UT Trad.Tools 4
L5' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L4' 5/8" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L3' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L2' 5/8" UT Trad.Tools 4 Trad.Tools Trad.Tools 4
L1' 1/2" Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools 4
L0' 5/8",1/2"
Trad.Tools Trad.Tools 4 Trad.Tools Trad.Tools
4
Note:ConditionState(CS)ratingsbasedonAASHTOCoReElementdescriptions
Panel
Point
Nominal
Thickness
DownstreamTruss UpstreamTruss
Brent Spence Bridge (I-71) over the Ohio River
059B00046N: Gusset Plate Evaluation - Lower Gussets
InboardPlate OutboardPlate CS InboardPlate OutboardPlate CS
U1 5/8",1/2" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U2 5/8" Trad.Tools Trad.Tools 3 UT UT 2
U3 5/8" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 3
U4 5/8" Trad.Tools Trad.Tools 1 Trad.Tools Trad.Tools 2
U5 5/8" Trad.Tools Trad.Tools 2 UT UT 2
U6 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U7 3/4" Trad.Tools Trad.Tools 2 UT UT 2
U8 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 3
U9 7/16" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 1
U10 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U11 3/4" Trad.Tools Trad.Tools 2 UT Trad.Tools 2
U12 3/4",3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U13 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U14 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U15 7/16" Trad.Tools Trad.Tools 2 UT UT 2
U16 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 3
U17 3/4" Trad.Tools Trad.Tools 2 UT UT 3
U18 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U19 9/16" Trad.Tools Trad.Tools 2 UT UT 2
U20 5/8" Trad.Tools Trad.Tools 2 UT Trad.Tools 2
U21 5/8" Trad.Tools Trad.Tools 2 Trad.Tools UT 2
U22 11/16" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U23 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U22' 11/16" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U21' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools UT 2
U20' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U19' 9/16" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U18' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U17' 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U16' 5/8" Trad.Tools Trad.Tools 2 UT UT 2
U15' 7/16" Trad.Tools Trad.Tools 2 UT UT 2
U14' 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U13' 3/4" Trad.Tools Trad.Tools 2 Trad.Tools UT 2
U12' 3/4",3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U11' 3/4" Trad.Tools Trad.Tools 2 UT Trad.Tools 2
U10' 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U9' 7/16" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U8' 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U7' 3/4" Trad.Tools Trad.Tools 2 UT Trad.Tools 2
U6' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U5' 5/8" Trad.Tools Trad.Tools 2 UT Trad.Tools 2
U4' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U3' 1/2" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U2' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
U1' 1/2",5/8"
UT Trad.Tools 2 Trad.Tools Trad.Tools
2
Note:ConditionState(CS)ratingsbasedonAASHTOCoReElementdescriptions
Brent Spence Bridge (I-71) over the Ohio River
059B00046N: Gusset Plate Evaluation - Upper Gussets
Panel
Point
Nominal
Thickness
DownstreamTruss UpstreamTruss
InboardPlate OutboardPlate CS InboardPlate OutboardPlate CS
M9 5/8" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 3
M11 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 3
M12 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
M13 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 4
M15 5/8" Trad.Tools Trad.Tools 3 Trad.Tools Trad.Tools 4
M15' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 3
M13' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 3
M12' 3/4" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
M11' 5/8" Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools 2
M9' 5/8"
Trad.Tools Trad.Tools 2 Trad.Tools Trad.Tools
2
Note:ConditionState(CS)ratingsbasedonAASHTOCoReElementdescriptions
Brent Spence Bridge (I-71) over the Ohio River
059B00046N: Gusset Plate Evaluation - Upper Gussets
Panel
Point
Nominal
Thickness
DownstreamTruss UpstreamTruss