Structural Engineering & Statics
where the load goes
Concept

Inspection — where it appears

Looking for a defect before it becomes a failure, which is a design variable rather than a maintenance one. A detail that cannot be inspected has to be designed as though its failure were undetectable, and whether a structure survives that failure is a separate question again.

Named by 10 essays across 3 fields — each of them below, with the objects they name alongside it.

Three details, and no material anywhere on the plot. Stress range against cycles to failure for three detail categorys — 160, 90, 36 N/mm² at two million cycles. The lines are parallel because they share a slope of three, and the spread between them is a factor of 4.4 in stress and therefore 88 in life. Nothing on this plot depends on the strength of the steel: the same detail in a grade twice as strong lies on the same line. At a stress range of 70 N/mm² the lives are 160: 6.8e+7, 90: 4.3e+6, 36: 2.7e+5 cycles. The knee in each line is the constant-amplitude limit, past which the slope becomes five.

The load that never came near failing anything

A detail survives sixty-eight million cycles at a stress range that another detail in the same steel survives two hundred and seventy thousand of. The two lie a factor of two hundred and fifty apart, and the material is not on the plot anywhere.

materials · Fatigue Four details, and no material anywhere on the plot. Stress range against cycles to failure for four detail categorys — 160, 112, 71, 36 N/mm² at two million cycles. The lines are parallel because they share a slope of three, and the spread between them is a factor of 4.4 in stress and therefore 88 in life. Nothing on this plot depends on the strength of the steel: the same detail in a grade twice as strong lies on the same line. At a stress range of 62 N/mm² the lives are 160: unlimited, 112: 2.1e+7, 71: 3.0e+6, 36: 3.9e+5 cycles. The knee in each line is the constant-amplitude limit, past which the slope becomes five.

The detail decides and the steel does not

A fatigue check contains no material strength anywhere. The same detail in a steel twice as strong lies on exactly the same line, because a fatigue life is decided by the geometry of a weld and by the stress range it sees — and two per cent of the traffic does most of the damage, because life goes as the inverse cube of the range.

connections · Detail category The crack length at which the strength stops mattering. Failure stress against crack length for a toughness of 100 MPa√m, with three steel grades drawn. The falling curve is fracture — Kc divided by Y times the root of pi a — and it does not know what the yield stress is. The horizontal lines are the grades. At 275 N/mm² the two cross at a crack 33.5 mm long; At 355 N/mm² the two cross at a crack 20.1 mm long; At 460 N/mm² the two cross at a crack 12.0 mm long. The stronger grade's transition is the shorter one — raising the yield stress does not raise the strength of a cracked member, it only shortens the crack that takes it away. At a working stress of 120 N/mm² the critical crack is 176.0 mm.

Designed to be found in time

A fatigue design that promises a detail will not crack is making a claim about a hundred years of traffic. A damage-tolerant one assumes it will crack, and sets the inspection interval from how long a crack takes to grow from the smallest size anybody can find to the largest the section can survive.

materials · Fatigue A preloaded joint, before and after it slips. Four preloaded bolts at 172 kN each, on one friction face at μ = 0.5. The joint carries 344 kN by friction with the bolts in tension and not in shear at all; past that it slips into bearing and carries 362 kN with the bolts now in shear. Two different mechanisms, one joint.

The hole made bigger so the steel would fit

A preloaded joint carries load by friction, and the friction is reduced by the shape of the hole the bolt passes through — not by how much steel the hole removes, but by a coefficient in a table. An oversize hole costs fifteen per cent of the resistance; a long slot costs thirty-seven. Both are provided because the steel would not otherwise line up.

connections · Slip-critical Nine-tenths of a tightening torque stretches nothing. Where the torque applied to the nut of an M20 grade 10.9 bolt goes, against the coefficient of friction in its thread and under its nut, taken as equal. The bottom band is the thread's lead — the only part of the work that stretches the bolt — the middle band is friction in the thread and the top band is friction under the nut. At μ = 0.14 the lead takes 11% of the torque, the thread 39% and the nut face 50%. At μ = 0.06 the lead's share is 22% and at 0.24 it is 6%, so a coefficient nobody measured decides how much of a specified torque arrives in the bolt as preload.

The torque that goes into the thread

A preload specified as a torque is a preload specified through two coefficients of friction that nobody measures. Nine-tenths of the torque on a bolt is spent turning against its own thread and the face of its nut, so a change in the grease moves the clamping force by half — and the one method that escapes it does so by yielding the bolt on purpose.

connections · Slip-critical Half the life is spent growing the first half-millimetre. The crack length against time for a detail starting with a 0.50 mm flaw under 800 cycles a day of the same five-band traffic the S-N calculation used, integrated by Paris's law. It reaches 1 mm after 91.2 years, 2 mm after 131.3, 10 mm after 172.9 and its critical length of 125.7 mm after 195.8. The curve is nearly flat and then nearly vertical, because the rate goes as the cube of ΔK and ΔK goes as the square root of the crack: the crack spends most of its life being too small to find and the rest being too large to ignore. The dashed lines are the crack lengths at which each band of traffic starts doing anything at all.

The loops a crack grows on

A Miner sum reduces a hundred years of traffic to a number and throws away everything below the cut-off — on this bridge, a third of the vehicles doing exactly none of the damage. Integrate the same spectrum as a crack instead and that third grows thirty-seven per cent of the crack, because a cut-off is a statement about a constant-amplitude test and a crack's threshold is a length rather than a stress. The two calculations disagree about the life by a third and about which vehicles matter entirely.

materials · Fatigue The same cycles, and two different lives. Two sequences made of exactly the same cycles — blocks of 6.00M at 40 N/mm² alternating with blocks of 0.22M at 90, on a detail starting with a 0.50 mm flaw. Taking the small cycles first, the crack reaches its critical 87.7 mm after 12.36M cycles; taking the large ones first, after 6.36M. Miner's sum at the moment of failure is 0.99 for the first and 0.68 for the second, so a rule that predicts failure at a sum of one is right to within a per cent about the first and 48 per cent unconservative about the second. The mechanism is on the axes: ΔK rises with the crack, so a large block met late finds a longer crack and does more with it.

The record played backwards

Miner's rule adds damage, and a sum has no order. A crack does, twice over: a large block met late finds a longer crack and does more with it, and an overload leaves a plastic zone that slows everything after it. The same cycles rearranged fail at 12.4 million or at 6.4, and a Miner sum that is right to one per cent about the first is out by half about the second. One cycle in four million can add fifty-four per cent to a life.

materials · Fatigue A crack at the cope's corner, and the hole its tip needs. A 457 × 190 beam end coped 150 mm long and 80 mm deep, reacting 350 kN of which 70 per cent comes and goes with traffic, to scale. A fatigue crack has grown 30 mm down the web from the corner where the cope's two cuts meet, the most stressed point of the coped section. At that depth the live load's range of stress intensity at its tip is 15.6 MPa√m, and a hole drilled with the tip inside it stops the crack only if its radius is at least (ΔK/10.5√fy)², 6.2 mm: a 12 mm hole. The crack and the hole together leave 341 mm of the 377 mm coped section below them.

The hole at the tip of the crack

The commonest reason to repair a coped beam end is a fatigue crack at the corner of the cope, and the commonest repair needs no plate at all: a hole drilled so that the crack's tip is inside it, turning a crack into a smooth notch that the traffic can no longer drive. The hole has to be big enough, and how big is set by the crack — its radius grows in step with the crack's length. A 30 mm crack at a stringer's cope needs a 12 mm hole, a 60 mm crack a 24 mm one. The repair stops working at about 100 mm, where the hole outgrows a site drill and the section left beside it runs out of capacity at nearly the same depth. Most of the crack's life is spent far shorter than that, which makes the repair a matter of how early the crack is found.

connections · Coped beam An old joint passes the bolts that have lost their preload. The chance that an M20 grade 10.9 bolt holds the inspection torque of 647 N·m without its nut turning, against the tension actually in it as a fraction of the minimum preload, for a joint new and 1 year old, 5 years old and 20 years old. New, a bolt at half the minimum preload passes 0% of the time and one at the minimum 83%; 20 years old, the bolt at half passes 80% of the time and one at a quarter 9%.

The wrench that reads the rust

The obvious check on a preloaded joint that has been in service for years is a wrench on the nut, and it measures the wrong thing. The nut holds against the bolt's tension times a friction bracket, and twenty years of rust raise the bracket until a bolt with half its preload passes four times in five. The washer that could have said more remembers only the day it was crushed.

connections · Slip-critical The silt hands the head back over decades, a season at a time. The basement is under five storeys, its water table 2.0 m above the design head and swinging ±0.5 m over the year, highest in April; pumped drains under its slab start 30 times as conductive as the ground. The head under the slab above the design head, against the years since the drains were new, for drains silting with time constants of 4, 8 and 16 years; dots, a standpipe read every October on the 8-year drains. With those drains the head reaches flotation in the wet season of year 24.1; the reading first exceeds 0.25 m in year 14.8, 9.4 years before.

The drain that fails a season at a time

A basement held at its design head by drains and a pump can fail suddenly, when the pump stops, or slowly, when fines settle in the drains and the head under the slab creeps up while the pump keeps running. The slow failure gives a standpipe read once a year a decade of warning, in its own time constants — if it is read in the wet season. And long before the silt floats the building on its own, it has made every stop of the pump more likely to.

equilibrium · Uplift

Named alongside it

The objects these essays reach for when they reach for this one.

FatigueCrack growthStress intensityCoefficient of frictionDetail categoryFrictionLimit stateMiners rulePreloadSlip resistanceStress concentrationStress range

All concepts