Finite Element Thermal Analysis of Deep Box-Girders

International Journal of Civil Engineering and Technology (IJCIET)
Volume 7, Issue 1, Jan-Feb 2016, pp. 128-139, Article ID: IJCIET_07_01_011

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ISSN Print: 0976-6308 and ISSN Online: 0976-6316
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FINITE ELEMENT THERMAL ANALYSIS

OF DEEP BOX-GIRDERS
Sallal R. Abid
Assistant Professor, Civil Engineering Department, College of Engineering,
Wasit University, Kut, Iraq
Salih Alrebeh
Engineering Projects Unit, Thiqar University,
Nasiriyah, Iraq
Nilde m Tayi
Assistant Professor, Civil Engineering Department, College of Engineering,
Gaziantep University, Gaziantep, Turkey
Mustafa zaka
Professor, Civil Engineering Department, College of Engineering,
Gaziantep University, Gaziantep, Turkey
ABSTRACT
A three-dimensional thermal analysis using the finite element method was
conducted in this research to evaluate the heat conduction in deep concrete
box-girder bridges considering the temperature change of air, the thermal
radiation from the sun and the speed of the wind. The current finite element
analysis has predicted the concrete temperatures effectively with temperature
errors ranged between 0.1 o C and 1.7 o C. The proposed finite element model
was then used to evaluate the distribution of temperature in deep concrete
box-girders considering the weather conditions of Gaziantep, Turkey. The
weather data including solar radiation, air temperature and wind speed for a
hot summer day were recorded from a specially installed weather station in
the campus of the University of Gaziantep. The results showed that the
AASHTO's gradient model was almost identical with the predicted
temperature gradients at the top and the bottom surfaces and along the clear
depth of the webs. However, the behavior along the top 1 m was different.
Key words : Air Temperature, Deep Box-Girder, Solar Radiation and
Temperature Gradient
Cite this Article: Sallal R. Abid, Salih Alrebeh, Nildem Tayi and Mustafa
zaka. Finite Element Thermal Analysis of Deep Box-Girders. International
Journal of Civil Engineering and Technology, 7(1), 2016, pp. 128-139.
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Finite Element Thermal Analysis of Deep Box-Girders
1. INTRODUCTION
Many types of structures are constructed in open environments, thus suffer a
continuous exposure to the fluctuation of climate. Bridges are among the structures
where the diurnal and seasonal variations in solar radiation and air temperature affect
the serviceability and may cause serious cracks and deflections [1-5], which influence
the live span of the bridge [6]. Many of the leading researches that were carried out
during the period extended from 1970 to 1990 [7-9] were the basis of the thermal
actions provisions of respected bridge design codes.
Most of the existing bridge design codes around the world, take into consideration
the temperature gradients that occur along the depth of the superstructure. The
temperature gradient models suggested by the design codes are generally linear,
multi- linear or nonlinear, which consider both the heating (positive) temperature
gradients and the cooling (negative) temperature gradients. The positive gradient
occurs after the continuous heating of the top surface during the hot hours of the day,
causing a significant rise in the temperature there compared to the tempe rature of the
interior sections, while the negative gradient occurs within the early morning hours
after long cooling phase at the top surface, which leads to a reverse temperature
differential.
AASHTO [10] specifies a bilinear gradient model for both the positive and the
negative temperature gradients. Four climate regions are categorized by AASHTO
according to the maximum solar intensity in USA and are defined from zone 1 to zone
4. The bilinear model consists of three temperatures gradients. The maximum at the
top surface (T1), followed by a linear decrease to the temperature gradient T2, which
is located 0.1 m below the top surface. The gradient decreases from T2 to zero at a
depth of 0.4 m for most cases. At the lower surface of the bottom slab, a temperature
gradient T3 is suggested, which varies linearly along the lower 0.2 m of the
superstructure.
In this paper, the influences of the daily change in the ambient air temperature and
the variation of the intensity of solar thermal radiation on the thermal budget in deep
box-girder bridges were studied using a three-dimensional finite element modeling of
an existing bridge. The temperature distributions along and across the slabs and the
webs of the girder and the vertical temperature gradients were inves tigated for the
climate of Gaziantep, Turkey. In addition, a comparison was made between the
predicted maximum temperature gradient and the design gradient of the AASHTO
bridge design specifications.
2. HEAT TRANSFER IN BOX-GIRDERS

The thermal changes of heat and temperature through the different parts of the bridge
cross section and along its span, which is a three-dimensional heat flow problem, is
controlled by the Fourier heat transfer equation [11],
(1)
where , and are the concrete density, specific heat and thermal conductivity,
respectively, while Q is the heat generated by cement hydration. The temperature T is
the main variable, which varies with x, y, and z.
The boundary conditions on the girder's surfaces are described by [11],
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Sallal R. Abid, Salih Alrebeh, Nildem Tayi and Mustafa zaka

(2)
where
is the heat exchange between the exposed surfaces and the surrounding
environment per unit area, while
,
,
are the direction cosines of the unit
vectors normal to the surfaces in the directions x, y and z.
(3)
The first term is the surface convection with the surrounding air, where
is the
convection coefficient of the surface,
is the surface temperature and
is the
temperature of the ambient air. The second term is the solar radiation absorbed by the
exposed surfaces, while the third term describes the reflected radiation from the
ground and other surroundings. Where, is the absorptivity of the surfaces, is the
global solar radiation on a horizontal surface,
is the reflection coefficient of the
ground, and is the tilt angle of surface. Finally, the last term represents the thermal
radiosity of the exposed surfaces to the atmosphere, where is the emissivity of the
surface and is the Stefan-Boltzmann constant. To solve Eq. (1) and to apply the
boundary loads that described in Eq. (3), the finite element package COMSOL
Multiphysics [12] was used.
Table 1 Material and thermal loads values
(
J/Kg K
1.7
Maximum
( )
1000
0.9
0.5
Minimum
Wind Speed Albedo
( )
28.6
21.6
29.5
0.1
3. VERIFICATION OF THE FINITE ELEMENT ANALYSIS

The current finite element model was compared with experimental results from a boxgirder bridge with variable cross-section along the span, which was constructed in
New Brunswick, Canada [13]. The comparison was conducted for the deepest crosssection in August 9, 1998 at 3:00 PM. The material thermal properties were assumed
equal to those considered by Sveinson [13], which are shown in Table 1, which also
lists the air temperature range, wind speed and the used albedo coefficient. Figure 1(a)
shows the compared section, in which the detailed cross-sectional dimensions and the
sections along which the thermocouples were installed are illustrated.
As shown in Figure 1(a), three sets of thermocouples were installed across the top
slab (TS1, TS2 and TS3), one set was installed across the bottom slab (BS1) and four
sets of thermocouples were installed across the two webs (W1, W2, W3 and W4).
Sections TS1, TS2 and BS1 have five thermocouples each, while the rest groups have
three thermocouples each.
The Average Absolute Error (AAE) and the Maximum Absolute Error (MAE) for
the eight sections are listed in Table 2. Both the AAE and MAE and for the eight
groups were noticeably small, where the AAE for the eight groups ranged between
approximately 0.1
and 1.1 , while MAE ranged from approximately 0.2
to
approximately 1.7
. The values of AAE and MAE show that the predicted
temperatures in the current study matched well with the compared field temperatures.
The finite element three-dimensional temperature distribution in the girder segment at
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3:00 PM is shown in Figure 1(b). Figures 2 to 4 show the degree of agreement

between the predicted temperatures and those recorded in the field along BS1, TS1
and along W1 and W2 sections, respectively. The figures clearly illustrate the good
agreement between the predicted and the experimental results and confirm the ability
of the current finite element model to analyze the box-girder with all boundary loads
efficiently. In addition to the presented verification, this models was verified in
previous works with an experimental box-girder [14, 15] and with other types of
concrete girders [16].
TS1
0.35 m
W1
0.72 m
12 m
TS2
TS3
W2
14 m
0.4 m
W3
0.96 m
BS1
W4
5m
(a) Cross-section
(b) Predicted temperature distribution at 3:00 PM
Figure 1 The deep box-girder, (a) the cross-section of the tested box-girder [13] and (b) the
three-dimensional finite element temperature distribution at 3:00 PM
Figure 2 Comparison of the finite element predicted and the field temperatures along BS1
section
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Figure 3 Comparison of the finite element predicted and the field temperatures along TS1
section
Figure 4 Comparison of the finite element predicted and the field temperatures along W1 and
W2 sections
4. TEMPERATURE GRADIENTS IN GAZIANTEP

To study the temperature distributions and the resulting gradients in deep box-girder
bridges in Gaziantep, air temperature, solar radiation and wind speed records were
collected from a weather station installed in the campus of the University of
Gaziantep. The June 2 was found to have the highest hourly global solar radiation
record along the summer of 2013 which was 1200
[17]. The maximum and
minimum air temperatures in the same day were 31.5 and 12.1 , respectively. The
wind speed on June 2 ranged from 0 to 1.9
with an average of 0.7
. To
simplify the numerical study, the cross-section of the top slab was simplified to be
prismatic with 0.7
thickness. To maximize the vertical temperature gradient along
the webs, the longitudinal axis of the bridge was considered along the east-west
direction so that the webs face the south and the north.
Figure 5(a) shows the vertical temperature distribution along the 14.0
depth of
the south web of the box-girder at different time steps [18]. The temperature
distribution at 6:00 AM represents those of the early morning hours, at which the top
surface is colder than the lower interior sections. The temperature of the top surface at
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6:00 AM was 26.6 , while the temperature in an interior point located 0.3 below
the top surface was about 30
as shown in Figure 5(a) and clearly illustrated in
Figure 5(b). After the continuous heating of the top surface during the midday hours,
which are associated with high solar radiation fluxes, the surface reached its
maximum temperature between 1:00 PM and 2:00 PM making a high differential
from the temperature of the lower layers along the top slab and the web as shown in
Figure 5(a). It is shown in Figures 5(a) and 5(b) that the temperature of the top surface
at 2:00 PM was more than 52 , while the temperature at 1.0
below was less than
25 . After the sunset, the temperature of the top surface decreased gradually while
the temperature of the interior points of the top slab stilled relatively higher as
illustrated in the temperature distribution at 8:00 PM. This decrease continued during
the night hours and early morning hours because of the effect of the surface
convection cooling and the surface long-wave radiation to atmosphere, reaching the
minimum surface temperature before the sunrise as shown in the temperature
distribution at 6:00 AM as illustrated in Figures 5(a) and 5(b).
A general notice, which can be recognized for each of the three time steps, is that
the temperature was almost constant along the clear depth of the web, which is
extended from the bottom surface of the top slab to the top surface of the bottom slab
as shown in Figure 5(a).
As shown in Figure 5(a), the temperature distribution across the bottom slab
differs from a time step to another. This variation is more clearly illustrated in Figure
6(a). As shown in Figure 6(a), the bottom surface of the bottom slab suffered higher
temperatures than the inside concrete points at 2:00 PM. This can be attributed to the
effect of the diffused solar radiation, the hot air temperature and the reflected
radiation from the ground and other surroundings. The temperature at the bottom
surface along the south web was 26.6
at 2:00 PM, while at 0.2
deeper in the
concrete of the bottom slab, the temperature decreased to 23.8 . Beyond the hot
hours of the day, the solar radiation reduced gradually and the air temperature
decreased leading to the starting of the cooling process on the bottom surface as
shown in the temperature distribution at 8:00 PM in Figure 6(a). The convection and
the re-radiation surface cooling continued until a reverse temperature distribution took
place, which reached its maximum before sunrise as shown in the temperature
distribution at 6:00 AM in Figure 6(a), in which the surface temperature was
approximately 19 , while it was approximately 23
at depths deeper than 0.2
from the bottom surface.
Figure 6(b) shows the temperature distribution across the section WS, which was
taken across the thickness of the south web at the mid-depth of the web. The figure
shows that the exterior surface temperature was higher than that of the interior surface
at 2:00 PM by 6.5 , while it was lower than that of the interior surface by
approximately 5 at 6:00 AM. As shown in Figure 6(b), at 8:00 PM, the temperature
difference between the exterior surface and the interior surface is minimal, where the
starting of the cooling phase set the surface temperature down.
Figures 7(a) and 7(b) show the temperature distributions at the three time steps
along the centerline of the 12 width of the top slab and the 5 width of the bottom
slab, respectively. It is shown in Figure 7(a) that for each of the three time steps, the
temperature was approximately the same along the central width of the slab, while
sharp temperature deviation occurred along the southern cantile ver slab and lower
temperature deviation occurred along the northern cantilever slab. At 6:00 AM, the
temperature decreased from approximately 30
at 0.5
away from the edge to
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approximately 21.5
at the southern edge, while the difference was only 3
along
the northern edge as shown in Figure 7(a). Similar results were observed at 8:00 PM
but with lower temperature differentials. At 2:00 PM, the temperature of the southern
edge was higher by about 4.5 as shown in Figure 7(a).
Figure 5 Temperature distributions along the centerline of the south web at different time
steps (a) along the depth of girder and (b) across the thickness of the top slab
Figure 6 Temperature distributions at different time steps (a) across the thickness of the
bottom slab (b) across the thickness of the south web
During summer, the sun rises from the northeast and sets at the northwest striking
with low angles and lower solar radiations. While during the hot hours, which
extended from approximately 10:00 AM to approximately 4:00 PM, sunrays strike the
bridge from the south with higher altitudes and higher solar radiation intensity. This
explains why the maximum temperature gradients occur at the southern surfaces [19].
This explanation can be obviously observed in the temperature distribution along the
bottom slab at 6:00 AM, which is shown in Figure 7(b). At the northern surface, the
edge was heated up after short time from sunrise due to the low altitude sunrays
concentrated there, while the completely shaded southern edge continued cooling
down. Thus, the temperature gradient was positive (heating) along the northern edge,
while it was negative (cooling) along the southern edge. The temperature distribution
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at 8:00 PM, which was close to the sunset, also confirms that the low altitude striking
of sunrays near the sunrise and sunset hours increased the temperature of the northern
surface of the bottom slab causing higher temperature gradients than at the southern
surfaces as shown in Figure 7(b).
Figure 7 Temperature distributions at different time steps (a) along the top slab (b) along the
bottom slab
Figure 8 The three-dimensional temperature distributions in the box-girder segment at 6:00

AM, 2:00 PM and 8:00 PM
As shown in the temperature distribution at 2:00 PM, the temperature gradient

occurred along the bottom slab was much higher that along the top slab at the same
time step. The temperature gradient was about 11
at the southern surface of the
bottom slab, while it was only about 4.5
at the southern surface of the top slab.
Figure 8 shows the three-dimensional temperature distributions in the box-girder
segment at 6:00 AM, 2:00 PM and 8:00 PM.
5. VERTICAL TEMPERATURE GRADIENTS

Figure 9 shows the distribution of the maximum temperature gradient along the whole
14
depth of the girder at the time steps of maximum positive and negative
gradients. The maximum negative temperature gradient occurred at 5:40 AM along
the south web, while it occurred at 5:20 AM along the north web as shown in Figures
9(a) and 9(b), respectively. The effect of the top slab's thickness is clear in Figures
9(a) and (b), in which it is shown that the gradient occurred within the thickness of the
top slab, while the temperature was almost constant within the clear height of the
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webs. The thickness of the top slab is 0.7 , while the thermal conductivity of
concrete is weak (1.7
) so that it is not adequate to conduct the surface's low
temperatures to the lower surface or even beyond the mid-thickness of the slab within
the night cooling hours. Thus, the deeper points of the top slab kept their hot
temperatures even after the long cooling hours, causing a reversed temperature
gradient within the thickness of the slab. The maximum surface negative temperature
gradients along the south and the north webs were 10.7
and 10.8 , respectively.
The temperature along the clear depth of the web was approximately 23
for
the south web and 25
for the north web at 5:40 AM and 5:20 AM, respectively.
Along the thickness of the bottom slab, the temperature gradients at the same time
steps were approximately 4 and 5 for the south and the north webs, respectively.
Figure 9 Vertical temperature gradients along the depth of the girder at different time steps
(a) along the centerline of the south web and (b) along the centerline of the north web
Three distinguishable regions can be recognized in the positive gradients along the
depth of the girder. First, a sharp nonlinear temperature decrease within the thickness
of the top slab or at most within the top 1 , followed by a region of a semi-constant
temperature, which mostly extends along the clear depth of web in addition to the top
0.7
of the bottom slab. The third region extends along the bottom 0.2
of the
bottom slab, within which the temperature shows a limited semi- linear increase up to
a maximum at the bottom surface of the bottom slab. The three regions are obvious in
Figures 9(a) and 9(b).
The maximum positive temperature gradients occurred between 1:20 PM and 1:40
PM. The maximum surface temperature gradients along the south and the north webs
were 29.6
and 28.6 , respectively. While at the bottom surface, the temperature
gradient was about 3 for both cases.
6. COMPARISON WITH AASHTO'S GRADIENT MODEL

Figure 10 shows the comparison between the predicted distribution of the maximum
positive temperature gradient, which is discussed in the previous section and the
design temperature gradient of Zone 1 of the AASHTO specification. Figure 10(a)
shows the comparison along the full depth of the box-girder, in which it is clear that
there is a good agreement with the AASHTO's gradient. For better visualization and
ease, only the top 2
and the bottom 1
of the girder were drawn against the
AASHTO's gradient in Figure 10(b). This is because as discussed in the previous
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section, the real variation occurred with these two regions, while the temperature was
almost constant along the clear depth of the web. As shown in Figure 10(b), the
maximum gradients at the top surface are almost identical, where the predicted
maximum temperature gradient was 29.6
, while the AASHTO's maximum
temperature gradient is 30 . At the bottom region of the girder, the behaviors and
the gradient values are also very close. The predicted gradient is almost linear along
the bottom 0.2
of the girder with a maximum gradient less than 3 , which is
almost identical with the linear variation of the AASHTO along this region and with
the gradient of the AASHTO at the bottom surface, which equals 2.8 .
Figure 10 Comparison of the predicted maximum vertical temperature gradient with the
gradient of the AASHTO (Zone1): (a) along the depth of the box-girder and (b) along the top
2 plus the bottom 1
The main difference between the two gradients is the behavior along the top
region (almost the top 1 ). The AASHTO gradient is bilinear with 7.8
at 0.1
from the top surface and reaching its zero value (constant temperature region) at 0.4
below. On the other hand, the predicted gradient distribution shows a nonlinear
variation along this region with much higher temperature gradients at these two
points. The predicted temperature gradients at 0.1 and 0.4 were 17.3
and 5.7 ,
respectively. Another important notice is that the predicted maximum temperature
gradient was calculated for recorded weather data; hence, it is inadequate for extreme
weather conditions. Considering extreme air temperature variation and solar radiation
intensity with long return period as worked by all design codes, the gradient would be
higher and hence the current AASHTO gradient would not be satisfactory for the case
of deep box-girders in the region of Gaziantep, Turkey.
7. COCLUSIONS
The heat conduction and the temperature distributions in deep concrete box-girder
bridges were studied in this research using the finite element method. External
thermal loads including solar radiation, reflected radiation fluxes, surface convection
cooling and surface re-radiation were considered in the thermal analysis. The finite
element model was verified with climate data and temperature measurements from an
existing bridge and was used to study the temperature and the temperature gradient
distributions in deep box- girder sections for the summer weather conditions of
Gaziantep in Turkey. Finally, the predicted maximum gradient was compared with the
AASHTO provisions. The main conclusions of the current study are:
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1. The proposed finite element thermal analysis could simulate the heat budget of the
real box-girder and predict concrete temperatures with high accuracy. The AAE
between the predicted and the measured concrete temperatures along different
sections were in the range of 0.1 to 1.1 , while the MAE was less than 1.7 .
2. During the day, the temperature of the exterior surfaces increase due to the high solar
radiation and the hot air, while because of the weak thermal conductivity of concrete,
the concrete interiors still cold which results in a positive temperature gradient with a
maximum at the exterior surface. On the other hand, due to the convection cooling
and the surface re-radiation, a negative temperature gradient occurs at the early
morning hours with a minimum temperature at the exterior surface. The predicted
maximum positive temperature gradients across the thickness of the mid-lengths of
the top slab, the bottom slab, the south web and the north web for the summer case in
Gaziantep were approximately 25 , 6 , 7 and 11 , respectively.
3. Due to the movement fashion of the sun during June, the maximum lateral
temperature gradients occur at the southern surfaces, while lower thermal gradients
occur at the northern surfaces of both the top and the bottom slabs. Along the
centerline of the top slab, the predicted maximum positive temperature gradients at
the southern and northern edges were approximately 9 and 3 . On the other hand,
the maximum positive gradients at the southern and northern edges for the centerline
of the bottom slab were approximately 11 and 7 .
4. For summer conditions of Gaziantep, the distribution of the maximum temperature
gradient along the 14
depth of the deep box-girder can be categorized into three
different regions. The first region is a sharp nonlinear temperature decrease within the
top 1 . Followed by a region of a semi-constant temperature along the clear depth of
the web in addition to the top depth of the bottom slab, ending with the third region
which extends along the lower 0.2
of the bottom slab, within which the
temperature gradient shows a limited semi-linear increase down to the bottom
surface.
5. The comparison of the predicted maximum vertical temperature gradient with the
AASHTO's design gradient of zone 1 shows that the predicted gradient meets well the
AASHTO's proposed temperature gradients at the top and the bottom surfaces. The
design gradients of zone 1 at the top and the bottom surfaces are 30
and 2.8 ,
while the predicted gradients at the same surfaces at the time of maximum gradient
were 29.6 and 3.4 . However, the gradient distribution behavior along the top 1
is different. AASHTO suggests a bilinear gradient distribution along the top 0.4
only, while the predicted gradient seems to vary nonlinearly within the top 1 .
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International Journal of Civil Engineering and Technology (IJCIET)

Volume 7, Issue 1, Jan-Feb 2016, pp. 128-139, Article ID: IJCIET_07_01_011