Pec-4072b Guarda Corpo Petrobras Coppe

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PEC-4072B

COMPOSITE MATERIALS HANDRAIL TESTING

Interested Party: Cogumelo Indstria e Comrcio Ltda FiberglassPultruded Products

COPPE Program: Civil Engineering

Project Coordinator: Eduardo de M. Batista

March 2003


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1. Introduction

This document includes a technical report describing the tests carried out on the industrial handrail

structural performance in accordance with COPPETEC PEC-4072 proposal, dated 15 October,

2002.

The tests were performed at the COPPE/UFRJ Structural Lab on 18 November, 2002, 21 January

2003 and 31 March 2003.

2. TEST DESCRIPTION

The procedures required for the tests were established by the Interested Party as follows:

Tests required by HPL for Platforms P-43/P-48

The three basic tests required are: horizontal static load, vertical static load and horizontal dynamic

load:

A) Horizontal Static Load : Three point loads (F) applied simultaneously to the top span of the

handrail. F is equal to 600N/m and the three load points are the following: F4 placed at 0.25L; F2

at 0.5L and F4 at 0.75L. After three minutes, the permanent deformation allowable is 8H/1000,where H is the height from the top of the handrail to the top of the deck;

B) Vertical Static Load: 1000N total force applied to two load points (500N) placed at 150mm

from each side of the central span. After three minutes, the permanent maximum deformation

allowable is 3mm.

C) Horizontal Dynamic Load (applied horizontally to the top rail): Application of a 180 Joules

load by dropping a Weight: 90kg; Height: 0.204m onto the handrail section, via cable and pulley.

Vertical post maximum deformation allowable amounts to 200mm while the weight is still applied.

Attached is a copy of the document provided by COGUMELO (Interested Party) indicating which

experimental procedures should be followed in order to confirm the aforementioned data. The

testing equipment was provided by the Lab and the applicable results are described below.

The load was applied vertically on the handrail upper section. The deformation of the handrail

section was measured and recorded immediately after the removal of the load from the handrail.

Overall condition of the columns, as well as the structural integrity of the handrail sections were

observed prior to, during and after each load application.


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3. GUARDRAIL PROTOTYPE TESTED

In order to conduct the tests, the Interested Party (COGUMELO) furnished two guardrail prototypes

manufactured with square section (5x5cm) tubes made of pultruded FRP in phenolic resin. Brown

is the color of the guardrail finishing and its dimensions are shown in Figure 1.

Shapes were secured to a U steel profile (height=254mm; weight= 22.7kg/m; thickness= 6.1mm)

previously fixed to a rigid metallic structure as shown in Figure 1 and attached photos. The

installation system established by COGUMELO as shown in Photo No.4 consists of 2 bolts per

post. To prevent the handrail sections from falling apart prior and during the compression tests,

each section of handrail was secured to a steel support by using two drilling screws on each side

of the sections

4. RESULTS ACHIEVED

4.1 Horizontal Static Load Test

The test completed on 18 November, 2002 was conducted in the presence of the following

Interested Party representatives: Mario Colao (Halliburton) Luiz Claudio Gonalves, Leonardo

(ABS) and Glauco Ribeiro (CENPES/Petrobrs).

The handrail section was horizontally loaded with three loads as shown in Figure 2. The loads

corresponded to a static loading equivalent to 600 N/m distributed along the upper part of the

handrail system, as follows:

Load on the upper part of the central post: F 1= 600 x L/2 = 600 x 2.42/2= 720 N (corresponding

load equal to F 1 /9.82=73kg)

Load on the center of the span: F 2 =600 x L/4 = 600 x 2.4/4 = 360 N (corresponding load equal to

F2 / 9.82 = 37kg)

The loads were previously measured in the presence of the Interested Party representatives. The

results achieved can be checked in the table below:


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F 1 = 75.2 kg x 9.82 = 728 N

F 2 = 36 kg x 9.82 = 354 N

The proper equipment analyzed the horizontal deformation on the upper part of the central post F 1,

and the rotation produced to the metal profile to which the handrail was secured. For this purpose,

a deflectometer with 10 -2 reading sensibility on the top of the central post and two deflectometers

with 10 -3 reading sensibility inside the hollow of the steel U profile were installed. This equipment is

shown in Figure 2.

The testing procedure is as follows:

Initial Step: Zero load, initial reference reading

100% Load Step: Total load, no reading

Final Step: Readings: three minutes after the weight impact

Below, the results achieved:

Step F 1 (10-2

mm) F 2 ( 10-3

mm) F 3 (10-3

mm)Initial 3400 0742 4627

100% Load - - -

Final (3 minutes) 3050 0786 4627

Displacement (mm) 3.50 0.044 0.000

The permanent maximum displacement allowable after the three-minute period subsequent to the

weight drop and taking into consideration the height (H) measured = 1100mm:

d max = 8.H/1000 8 x 1100/1000 = 8.80mm

Therefore, the total displacement achieved in the test (even disregarding the torsion rotation of the

U steel profile) is within the limits deemed allowable.

d max = 3.5mm < d max = 8.80mm


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The guardrail prototype was approved in the horizontal static load test

4.2 Vertical static load test

This test was conducted on 21 January, 2003 in the presence of the following Interested Party

representatives: Salsio Schuelter (Cogumelo), Lus Cludio (ABS), Mrio Colao (Halliburton),

Mrio Canedo (Suprimar / Mau Jurong) and Glauco Ribeiro (CENPES/ Petrobrs).

The vertical static load test was conducted with two 500N loads, each one displaced 150mm from

the center of the handrail spans. Photo No.1 shows the test in progress.

The readings at the central point of the loaded span arrow were taken from a Mitutoyo dial

indicator with 10 -2 reading sensitivity.

The reading results are the following:

Readings Steps Measured values (10-2

mm)Initial reference reading, zero load. 2091

100% load 1925

Zero load after three minutes 2085

Final arrow after three minutes 0.06

Considering that the permanent arrow maximum allowable value is 3mm, the guardrail prototype

was approved in the static vertical load test.

4.3 Dynamic horizontal load test

This test was conducted on 31 March, 2003 in the presence of the following Interested Party

representatives: Salsio Schuelter (Cogumelo), Lus Cludio (ABS), Mrio Colao (Halliburton),

Mrio Canedo (Suprimar/MauJurong) and Glauco Ribeiro (CENPES/ Petrobrs).


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The test consisted of a concentrated load created by the 204mm course fall of a 90kg load and

placed on top of the central column. This load corresponded to the potential force of F=90 x 9.82 x

0.204=180.3 Joules. The equipment used in this test is shown in Figure 3. The free fall started

immediately after the bowknot wire was cut. The course of the free fall was controlled by a steel

cable from the Lab rolling assembly, which was previously secured to the loading system.

The 91.2kg load application was carried out by using a set of weights previously measured in the

presence of the Interested Party representatives. The length of the free fall course was 20.5cm

measured with a measuring tape (this measurement was taken by positioning the weight height

after being suspended with the rolling assembly cable). Therefore the impact load corresponded to

a potential force of: F= 91.2 x 9.82 x 0.205 = 183.6 Joules.

The horizontal deflection measurements on top of the central post were taken with a metallic

measuring tape graduated in mm and evaluated against a fixed reference post, independent from

the prototype.

After the impact of such weight, the prototype remained fixed to the steel profile. Photographs of

the test are attached herein.

Also after the impact, the fixed connectors remained intact, showing no signs of structural

degradation. The 32mm horizontal displacement was measured on top of the central rail while still

bearing the weight applied of 91.2kg.

Considering the 200mm maximum allowable displacement value obtained, we can well conclude

that the guardrail prototype was approved in the dynamic horizontal load test.

5. Conclusions

The FRP composite materials handrail prototypes were approved in the three tests proposed.


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ANNEX 1: Figures

Figure 1: Chart of the handrail prototype secured to a steel U profile.

Installation: 2 bolts, d=10

Steel U profile: 254 x 22.7


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Figure 2 : Chart of static horizontal loading and equipment system to measure

displacements.


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Figure 3: Chart of the dynamic horizontal load test

Weight= 91.2kg

Free fall =20.5cm


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ANNEX 2: Photos

Photo No.1: Vertical static load test set up


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Photo No. 2: Dial indicator (reading sensitivity= 10-2mm) for measurements during vertical

static load tests.


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Photo No. 3 Chart of the horizontal dynamic load test


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Photo No. 4: Securing system with two screws, d=10 per post.


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Photo 5: Final displacement measurement after load impact during horizontal dynamic load

test.


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ANNEX 3: Documentation

Doc.1: Test specifications.


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ANNEX 4: Evaluation of handrail test results with 1.5m maximum span

between posts (3m section)

The tests described in this document refer to 2.4m handrail sections. The sections tested

measured 3.0m (1.5m span between posts) therefore:

(a) Horizontal static load test

Correction of the load applied: F x 3/2.4 = F x1.25

Result obtained for the 2.4m span = 3.5mmCorrection of the arrow for the 3.0 span: 3.5 x 1.25 = 4.38mm < 8.8mm

Approved

(b) Vertical static load test

Correction of the measured arrow: F x (1.5/1.2)2 = F x 1.56

Result obtained for a 2.4m span = 0.06mm

Correction of the arrow for the 3.00m span: 0.06 x 1.56 = 0.09mm < 3mm.

Approved

(c) Horizontal dynamic load test

Result obtained for a 2.4m span: 32mm

Maximum value allowable: 200mm

Therefore, as the value measured equal to 16% of the maximum value allowable, the

increase of the guardrail spans from 2.4m to 3.0m, certainly will not produce an arrow that exceeds

200mm.

Approved

Therefore we may conclude that the handrail manufactured with FRP composite materials in

phenolic resin and presenting the maximum span of 1.5m between the posts was approved.


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COMPOSITE MATERIALS INDUSTRIAL HANDRAIL TESTS

Rio de Janeiro, April 2, 2003

Project Coordinator

Civil Engineering Program Coordinator

COPPETEC Foundation CEO

Pec-4072b Guarda Corpo Petrobras Coppe

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