5.1. Configuration and measurement locations
The temporary measurement system consists of 80 strain gauges, which were installed on chain elements on both inflow and outflow side, in order to measure elongation variation, and track the structural behaviour during reconstruction. Data obtained from the measurement system also provides information on the changes in elongation of the structure due to non-reconstruction loads (e.g., due to temperature changes, or other meteorological effects), which can be used to better understand the behaviour of the structure. In addition, the temperature of the air and the steel structure are recorded as well. Continuously processed data made it possible to determine intraday, weekly and monthly measurement trends and changes between individual reconstruction stages.
The purpose of the measurement is to assess the stress induced in the chain elements under varying loads to infer the rotational capacity of pins. Eight distinct locations along the chains are measured. Four measurement sites (H1 - H4) are positioned at the bridge abutments on both the inflow and outflow sides, while four other sites (P1 - P4) are established at the pylon on the Buda side, similarly to the proof load test as shown in
Figure 3 and
Figure 4. Each location undergoes measurements on both the lower and upper chain elements. At the abutments (measurement sites H1 - H4), strain gauges are placed on the end of the parallel part of the chain elements (located at 100 mm from the rounding of the pin head in the axial direction, near the directional change at the structural bearing). Strain gauges are installed on both sides of the chain bars, 20 mm from the lower and upper edges. Accordingly, a total of four strain gauges per measurement location are used at the abutments. This approach allows for the independent determination and comparison of changes in bending moment and normal force within the chains. The same considerations are done for strain gauges at the pylon (measurement sites P1 - P4), except additional sensors are installed at the neutral axis of the chain elements. Thus, six sensors per measurement location are used at the pylon, which are illustrated in
Figure 9.
HBM PMX data acquisition systems are used for accurate, reliable, and flexible measurement, which are ideally suited to process high data volumes for long-term multi-channel applications. Biaxial strain gauges, with nominal resistance of 350 Ω, are installed with temperature compensation. Measurement and data logging are controlled using CatmanEasy, the software of HBM. A sampling rate of 1 Hz is applied during data acquisition.
5.2. Reconstruction stages
A detailed organisation plan for the current reconstruction was drawn up. This paper does not describe the entire construction process, only those stages that are relevant for measurement evaluations, which are the followings:
1. crane track is built on the superstructure (15.07.2021),
2. suspended scaffolding is installed, while reinforced concrete slab is demolished in the main span (01.08.2021),
3. old steel stingers are dismantled in the main span, new orthotropic deck is installed in half of the main span, suspended scaffolding is installed in the side spans (03.11.2021),
4. the old concrete slab and steel stringers are dismantled on the entire bridge, the new orthotropic deck is installed between pylons, sidewalks in the main span are dismantled, suspended scaffolding is dismantled (03.01.2022).
For illustration purposes,
Figure 10 shows the superstructure of the bridge between phases 3 and 4. The suspended scaffolding was installed in the side spans, and the old deck system (concrete slab and steel stringers) was already demolished. This erection phase gave a dominant loading situation from static point of view; thus, the maximum load was applied in the middle span, and the minimum in the side spans. It was expected that this erection phase could make the hinges rotate.
5.3. Measurement results
The strain gauge measurement outcomes are presented in a segmented way. First, longer time data series are presented, which aims to offer an overview of the daily cyclical elongation variations triggered by temperature changes and significant construction phases. Initially, observations from measurement site P1, at the pylon, are synthesized.
Figure 11a,b showcase the findings of strain gauges P1/1-P1/4 (upper chain) and P1/5-P1/8 (lower chain). These graphs highlight substantial intraday temperature-induced fluctuations, recording a disparity of 100-120 μm/m (21-25.2 MPa) between the lower and upper extreme fibres due to temperature shifts, resulting in additional stress on the structure. Meanwhile,
Figure 11c illustrates the strain changes of sensors P1/9-P1/12 along the neutral axis. A more notable alteration is noted from late November to early December 2021, primarily attributable to construction activities involving the construction stages of the deck plate between the pylons, and the demolition of the reinforced concrete deck plate and steel stringers in the side spans. Strain gauges positioned close to the upper extreme fibres (P1/1-P1/2 and P1/5-P1/6) experience increased tension, whereas those near the lower extreme fibres (P1/3-P1/4 and P1/7-P1/8) endure higher compression. Across the neutral axis (
Figure 11c), all sensors indicate a marginally heightened tension starting from early December 2021.
Through averaging and subtracting the measured values from the respective strain gauges, the strain change curves depicting the impact of normal force Δε
N and bending moment alterations Δε
M are derived (
Figure 12). It is evident that normal forces undergo minimal change, while bending moment notably increases in both the upper and lower chains. The measurement charts display continuity, apart from minor fluctuations within the day, suggesting no movement in the chain links during this timeframe.
The assessment of measurement results at test sites also includes separate Sundays (
Figure 13), when no construction work occurred, enabling analysis of solely meteorological influences, primarily temperature changes. On 27th June 2021, variations of 110-125 μm/m are observed in daily strain near the upper extreme fibre of P1/1 and P1/2 (inflow side, upper chain, Buda side). Correspondingly, lower values, spanning 80-100 μm/m and 60-65 μm/m, are recorded on 4th July and 11th July 2021, respectively, mainly at P1/2 (south side of the chain). The recorded air temperatures in Budapest ranged from 19-31 °C across these days, with a temperature variation of 11-12 °C, although no significant changes occurred in the structural behaviour during this period. The impact of daily temperature fluctuations (warming and cooling) is distinctly evident in the measurement results. The variations caused by daily temperature changes are comparable with strains observed during the proof load test. Maximum measured daily strain, normal force and bending moment variations for the pylon sites are shown in
Table 1. In the upper chain elements, the maximum change is 125 μm/m, while it is 140 μm/m for the lower ones in the extreme fibres. In the neutral fibre, the magnitude of maximum strain variation is 80 μm/m. Results show quasi linear strain pattern within the sections. Notably, for sensor sets P1 and P3, larger strains (tension) are observed in the top fibres compared to the bottom ones. Conversely, for sensor sets P2 and P4, an inverse pattern emerges. This trend illustrates a linear increase towards the top extreme fibres, influenced by additional moments in the chain links.
Maximum normal force and bending moment variations at the pylons (P1-P4) due to proof load test, reconstruction and daily temperature fluctuation are derived according to the methodology described in
Section 4.3; results are summarized in
Table 2. The analysis of the data suggests that daily temperature shifts could lead to additional bending moments up to 158% (P1, upper chain) compared to the values observed during the proof load test (~80% of the design live load of the bridge). Furthermore, normal force measurements even show a 42% higher value (P2, lower chain) than those registered during the load testing. This highlights the high sensitivity of chain bridges to temperature fluctuations, where geometric stiffness plays an important role. It also shows, if the bending moment applied by the live load of the bridge would make the pins rotate, the daily temperature change would also make it on the daily bases. However, most of the pins did not rotate during the load test, even under the internal forces caused by the temperature change. Both proves, that pins of this historical bridge are stuck, and the static skeleton of the structure can be assumed as fixed within the static calculations under the live load and meteorological loads.
Furthermore, reconstruction, due to reduced self-weight, notably intensifies the impact on normal forces and bending moments. For instance, the bending moment variation increased by approximately 380% in the upper chain at location P1. Although lower chains had relatively small bending moments (<30 kNm) during the proof load test, normal forces experienced a significant increase, measuring 208% higher at location P3. These results emphatically underscore the dominance of dead load and self-weight in the case of chain bridges. The measurement results also showed, that even the most significant bending moment change during the construction could not initiate the rotation of the pins, they are strongly corroded and fully stuck.
For easier interpretation and presentation of results, cross-sectional resistances of chains with nominal geometrical dimensions are also evaluated for comparison purposes to the measured internal forces. In 2015, statistical evaluation of previous tensile tests, from 1913 and 1948, was carried out at the BME Department of Structural Engineering and the characteristic yield strength fyk was determined. Based on the measured values the design resistances are calculated by Eurocode 3 formulae, as follows: the pure tensile resistance of a chain using nominal cross-section properties is NRd = A × fyk / γM0 = 1274 cm2 × 28.1 kN/cm2/ 1.0 = 35799 kN and bending moment resistance of a cross-section is MRd = W × fyk / γM0 = 7749 cm3 × 28.1 kN/cm2/ 1.0 = 2177.5 kNm. It can be seen that the largest normal force and bending moment change within the chain system coming from the proof load test, reconstruction or temperature change reaches only 13% of the tensile resistance and 33% of the bending resistance, respectively.
It is crucial to highlight that chains with fixed pins are subjected to a combination of axial tension and bending moments, compounded by the effects of corrosion on their cross-sectional properties, thereby diminishing their overall resistance.