Fiber Reinforced Polymer (Frp) Composites Rebar
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The document discusses fiber reinforced polymer (FRP) composites as a non-corrosive alternative to traditional steel rebar in concrete applications, emphasizing their benefits in durability and performance. It outlines the characteristics, manufacturing processes, standards, and various applications of FRP materials in construction, particularly in bridge decks and other structures. The report highlights successful installations and the potential for cost savings through reduced maintenance needs over time.
Fiber Reinforced Polymer (Frp) Composites Rebar
- 1. FIBER REINFORCED POLYMER (FRP) COMPOSITES REBAR John P. Busel Director, Composites Growth Initiative American Composites Manufacturers Association May 23, 2012
- 2. Outline About ACMA Introduction FRP Materials FRP Bars Standards & Specifications Applications Summary
- 3. Formed in 1979 World’s largest composites trade association representing: 3 Manufacturers Material Suppliers & Distributors Composites Industry 3000+ Companies 280,000+ employees North America Industry Consultants Academia About ACMA
- 4. ACMA Industry Council Mission - Promote the use and growth of FRP reinforcement (rebar, tendons & grids) in concrete and masonry applications through development of quality procedures, industry specifications, performance standards, and field application guidelines.
- 5. FRP-RMC Manufacturers BP Composites Composite Rebar Technologies, Inc. Hughes Brothers, Inc. Marshall Composite Technologies, Inc. Pultrall, Inc.
- 6. Introduction The Problem - Corrosion Corrosion and deterioration of steel reinforced concrete Mitigation techniques - High costs to rehabilitate and remediate structures Safety - Construction zones and detours The Solution – FRP Rebars Non corrosive concrete reinforcement Increase service life (durability) Hundreds of applications in service in North America
- 7. Traditional Approach to Corrosion Problems Reduce, Eliminate, or Negate the Current Flow of the Electrochemical Corrosion Cell Inherent With Steel Reinforced Concrete Admixtures Increase Concrete Cover Efforts to reduce permeability & mitigate cracking - HPC Alter Concrete Mix Membranes & Overlays Epoxy coated steel Cathodic protection Sacrificial anodes
- 8. FRP Materials Why are composites different?
- 9. FRP Materials Constituent Constitue nts s What is FRP? Fibers Provide strength and stiffness Carbon, glass, aramid Matrix Protects and transfers load between fibers Polyester, Epoxy, Vinyl Ester, Urethane Fibe r CompositeMsatrix Creates a material with attributes superior to either component alone! fibers and matrix both play critical roles in the composites material...
- 10. What is different? FRP is Anisotropic High strength in the direction of the fibers This anisotropic behavior affects the shear strength, dowel action, and bond performance FRP does not exhibit yielding: the material is linear elastic until failure Design should account for lack of ductility Member does have substantial deformability
- 11. Composites Features Impervious to chloride ion and chemical attack Tensile strength is greater that steel ¼ the weight of steel Transparent to magnetic fields and radar frequencies Electrically non-conductive Thermally non-conductive
- 12. Where should FRP rebar be used? Any concrete member susceptible to corrosion by chloride ions or chemicals Any concrete member requiring non-ferrous reinforcement due to Electro-magnetic considerations As an alternative to epoxy, galvanized, or stainless steel rebars Where machinery will “consume” the reinforced member ie. Mining and tunneling Applications requiring Thermal non-conductivity
- 13. Tensile Stress-Strain Characteristics 0 1 2 3 Tensile Strain (%) 400 300 200 100 0 Tensile Stress (ksi) FRP Composite Types CFRP AFRP GFRP 2000 MPa 1000 MPa Linear elastic behavior to failure No yielding Higher Ultimate Strength Lower Strain at Failure Typical Steel Rebar
- 14. FRP Properties Steel GFRP CFRP AFRP Yield Stress ksi (MPa) 40 - 75 (276 - 517) N/A N/A N/A Tensile Strength ksi (MPa) 70 - 100 (483 - 690) 70 - 230 (483 - 1600) 87 - 535 (600 - 3690) 250 - 368 (1720 - 2540) Elastic Modulus X 103 ksi (MPa) 29 (200) 5.1 - 7.4 (35 - 51) 15.9 - 84 (120 - 580) 6.0 - 18.2 (41 - 125) Yield Strain % .14 - .25 N/A N/A N/A Source: ACI 440.1R-06
- 15. Factors Affecting Material Characteristics Type of fiber Fiber volume Type of resin Fiber orientation Quality control procedures during manufacturing Rate of curing Void content Service temperature
- 16. Coefficient of Thermal Expansion -6 / CTE (10 o F ) Material Longitudinal Direction Transverse Concrete 4 ~ 6 4 ~ 6 Steel 6.5 6.5 GFRP 3.5 ~ 5.6 »12 CFRP - 4 ~ 0 41 - 58 AFRP - 3.3 ~ - 1.1 33 - 44 • Values of CTE differ between FRP materials and concrete.
- 17. Effect of High Temperatures Resins will soften due to excessive heat The tensile, compressive, and shear properties of the resin diminish when temperatures approach the Glass Transition Temperature, Tg Tg values are approximately 250oF (120oC) for vinylester resins which are typically used with GFRP rebars Tg lowers as a result of moisture absorption
- 18. FRP bars Looks are deceiving
- 19. Pultrusion Process Manufacturing Processes Resin Heated Die Most products are manufactured with this process Cured Profile
- 20. FRP Bar Types Materials Glass/ vinylester Carbon/ vinylester Forms Solid
- 21. FRP bar types Surface Ribbed (a) Sand Coated (b) Wrapped and Sand Coated (c) Deformed Helical a) b) c)
- 22. Innovation – hollow bar - coming soon Courtesy of Composite Rebar Technologies, Inc.
- 23. Bar Sizes Bar Size Nominal Diameter Imperial Metri c Imperial Metric Inches mm inches mm #2 6 0.25 6.35 #3 10 0.375 9.53 #4 13 0.4 12.7 #5 16 0.625 15.88 #6 19 0.75 19.05 #7 22 0.875 22.23 #8 25 1 25.4 #9 29 1.125 28.65 #10 32 1.25 31.75
- 24. Strength and Modulus Grades Strength grade is based on ultimate tensile strength of the bar. Lowest grade is 60 ksi Strength is provided on 10 ksi increments Grade F 60 f * >60 KSI Grade F 300 fu >300 KSI Modulus grade corresponds to minimum modulus of the selected bar.
- 25. Standards & Specifications Translating research into industry standards
- 26. ACI – rebar design guideline Design principles well established through extensive research Guideline documents published in North America, Europe, Japan Non-mandatory language
- 27. ACI – rebar, materials spec ACI 440.6-08, mandatory language (standard document) Provisions governing testing and evaluation for certification and QC/QA Describes permitted constituent materials, limits on constituent volumes, and minimum performance requirements
- 28. ACI – rebar, construction spec ACI 440.5-08, mandatory language (standard document) GFRP bar preparation, placement (including cover requirements, reinforcement supports), repair, and field cutting
- 29. AASHTO design guide New AASHTO LRFD design guide specifications published 11/2009 Bridge decks and traffic railings, glass FRP (GFRP) bars Specific properties of GFRP reinforcement, design algorithms and resistance factors, detailing, material and construction specifications
- 30. ACI Test methods
- 31. Rebar Test Methods ACI 440.3R-04 – (12) test methods for FRP rebars ASTM D30 (Composite Materials) and D30.05 (Structural Test Test Method Methods) committees, ASTM Standard now D30.10 B.1. Bar Cross-Section D7205-06 (R11) B.2. Bar Tension D7205-06 (R11) B.4. Bar Transverse Shear D7617-11 B.6. Bar Alkaline Tension WK27200 B.8. Bar Creep Rupture D7337-07 App. A. Bar Anchors D7205-06 (R11)
- 32. Canada - Highway Bridge Design Code Technology transitioned from government-subsidized research projects to actual commercialization Experience gained on viability of construction management practices where FRP reinforcement is adopted through traditional bid letting processes and competitive bidding from multiple FRP bar suppliers
- 33. Canadian Standards CSA S807 – 09 Qualification and QA criteria
- 34. Quality Assurance - Verification and traceability of bar properties
- 35. Durability ISIS Canada reports on Durability performance of GFRP bars in Bridge Decks in Service for 8-10 years Multiple reports from several institutions
- 36. NO Degradation of GFRP bars found !
- 37. …..a closer look
- 38. Applications Many installations and growing
- 39. TEA-21 FY 98-03 - IBRC Program 124 FRP Projects - $87M funded • 44 decks • 14 rebar • 33 repair • 6 tendons • 27 others (i.e. FRP glulam) 19 states with FRP decks Future funding - uncertain
- 40. Installations Today In the U.S. >190 installations that use FRP composites >50 installations where FRP bars are used in bridge decks 15 states (CO, FL, IA, IN, KY, MO, NC, NY, OH, OR, TX, UT, VT, WI, WV) use FRP bars in bridge decks In Canada, >195 installations that use FRP composites 190 installations use FRP bars in bridge decks, parapets, barriers, sidewalks
- 41. Applications Cast in Place Precast Top mat Top and bottom mat Decks, parapets, sidewalks Other applications: tunneling (soft eye, seawalls, MRI rooms, light rail foundations, railway girders, culverts, and many more.
- 42. FRP Rebar for Decks & Approach Slabs Applications Sierrita de la Cruz Creek Bridge USA Pierce Street Bridge, Lima OH USA Wotton, Quebec Canada Taylor Bridge Manitoba Canada
- 43. Morristown Bridge Vermont 2002 Concrete cast-in-place May 2002 Bridge opened to traffic July 2002 Courtesy of Pultrall, Inc.
- 44. 3. Impact (Courtesy of Hughes Brothers, Inc.) Emma Park Bridge, Pleasant Grove, Utah DOT, 2009
- 45. Emma Park Bridge Full Depth Precast – top & bottom mat Cost premium in 2009 to use GFRP over Epoxy bar 14% greater deck cost – due in large part to additional girders On a 1:1 basis, GFRP bars equal in unit price to epoxy steel Polymer overlay adds 3% to cost of bridge – not needed with GFRP bar Additional 6 years of service life makes up for premium Typical service life today is 25 to 30 years for decks
- 46. Emma Park Bridge Courtesy of Hughes Brothers, Inc.
- 47. 53rd Ave Bridge Bettendorf, IA 2001 Courtesy of Hughes Bros.
- 48. Floodway Bridge, Manitoba, Canada 2 Bridges 8 spans each 2 Lanes Each Bridge 142 feet typical span 1136 feet total length (1/5 mile) 50 foot Wide 9 inch thick Deck Slab 8 feet Girder Spacing
- 49. Floodway Bridge, Manitoba, Canada Largest Steel Free Deck Project Largest FRP reinforced bridge in the world 8 Truckloads of GFRP Rebar 150 Tons of GFRP = 1.2 million lbs of steel rebar (30 truckloads) Primarily #8 and #3 Longitudinal #6 Transverse 3200 CY concrete (6400 tons)
- 50. Floodway Bridge, Manitoba, Canada Courtesy of Hughes Bros.
- 51. O’Reilly Bridge - Canada New anchor head used Courtesy of Pultrall, Inc.
- 52. Noden Causeway Prestressed/precast deck Courtesy of Pultrall, Inc.
- 53. Noden Causeway Courtesy of Pultrall, Inc.
- 54. Noden Causeway Courtesy of Pultrall, Inc.
- 55. Prefabricated FRP stay-in-place reinforcement panels Large-size 24’ x 8’, double-layer stay-in-place (SIP) reinforcing panels pre-assembled using off-the-shelf pultruded GFRP components 1.5” I-bars (4” o.c. perpendicular to traffic) Three-part cross rods (4” o.c. parallel to traffic) 1/8” thick epoxy bonded form plate Vertical connectors
- 56. Deck construction Day 1: SIP panels setting and anchoring
- 58. Tunneling, soft-eye Yi Shan Station Shanghai Courtesy of Hughes Brothers, Inc.
- 59. Seawalls Courtesy of Marshall Composite Tehnologies
- 60. Summary Complete set of guides, test methods and standards are available for GFRP bars Many bridges built with GFRP bars and performing well Non-proprietary solution, traditional supply chain acquisition & installation in place Extended service life of GFRP reinforced decks is expected Many practices adopted for corrosion protection are not necessary with FRP bars Holistic view of bridge deck construction makes FRP bars the best value proposition
- 61. Composites Conference www.acmashow.org • COMPOSITES 2013 • Orange County Convention Center, Orlando, FL • January 29-31, 2013 • Over 4,000 attendees • Sessions on infrastructure and construction • Expo with suppliers and manufacturers
- 62. LRFD – Pultruded Composites Pre-Standard released 2010 Ch. 1 General Provisions Ch. 2 Design Requirements Ch. 3 Tension Members Ch. 4 Compression Members Ch. 5 Flexural and Shear Members Ch. 6 Combined Forces & Torsion Ch. 7 Plates and Built-Up Members
- 63. Code of Standard Practice Industry Guidelines Released December 2011 Balloting for ANSI standard in progress ANSI Standard approved in March 2012 Publish, June 2012
- 64. Thank You John P. Busel Director, Composites Growth Initiative American Composites Manufacturers Association (ACMA) P: 914-961-8007 E: jbusel@acmanet.org