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 an