SIKA® CARBODUR® CALCULATION SOFTWARE

PROJECT: Път III-906 - Мост при км 13+697

ELEMENT: Главна греда - усилване за огъващ момент
INDEX

1.- DESIGN CRITERIA AND REGULATIONS......................................................................................................................... 3

2.- CALCULATION ASSUMPTIONS..................................................................................................................................... 3

2.1.- Geometry...................................................................................................................................................... 3
2.2.- Concrete........................................................................................................................................................ 3
2.3.- Reinforcing steel............................................................................................................................................ 3
2.4.- Strength reduction factors............................................................................................................................. 4
2.5.- Load factors................................................................................................................................................... 4

3.- FRP STRENGTH............................................................................................................................................................ 4

3.1.- Main FRP reinforcement................................................................................................................................ 4

4.- ANTICIPATED COMBINATIONS OF LOADS................................................................................................................... 4

4.1.- Initial loads.................................................................................................................................................... 4
4.2.- Expected loads (strengthening design)........................................................................................................... 4

5.- RESULTS..................................................................................................................................................................... 5
5.1.- Summary of results........................................................................................................................................ 5
5.2.- Ultimate limit states...................................................................................................................................... 5
5.3.- Serviceability limit states............................................................................................................................... 9
5.4.- Additional check............................................................................................................................................ 10
5.5.- FRP arrangement........................................................................................................................................... 11

6.- PRODUCT SPECIFICATION........................................................................................................................................... 11

6.1.- Bonded SikaWrap® fabrics............................................................................................................................. 11
6.1.1.- Concrete surface preparation.................................................................................................................. 11
6.1.2.- SikaWrap® fabrics.................................................................................................................................... 12
6.1.3.- Epoxy Adhesive........................................................................................................................................ 12

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 INDEX
6.1.4.- Application procedure............................................................................................................................. 13

7.- LEGAL DISCLAIMER..................................................................................................................................................... 14

8.- ABOUT SIKA® CARBODUR® CALCULATION SOFTWARE................................................................................................ 14

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1.- DESIGN CRITERIA AND REGULATIONS
Flexural FRP strengthening of beam

Concrete Society Technical Report No. 55 (TR 55): design guidance for strengthening concrete structures using fibre
composite materials, Third Edition 2012.

EN 1992-1-1. Eurocode 2: Design of concrete structures - Part 1-1: General rules and rules for buildings.

Country: Bulgaria

2.- CALCULATION ASSUMPTIONS

2.1.- Geometry
Cross section = T-Beam
Web width = 400 mm
Total height = 1540 mm
Width of flange = 1800 mm
Height of flange = 440 mm

1800

440
1540

400

2.2.- Concrete
Compressive strength of concrete
Concrete strength (fck) = 30 MPa
Cylinder specimen = 30 MPa
Cube specimen = 37 MPa

2.3.- Reinforcing steel

Reinforcement layers
Steel fyk Es Number x Ø
Top layer d1 mm
(MPa) (MPa) (mm)
1. 52 (B500) 500 200000 9 x 12.0

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 Steel fyk Es Area
Bottom layer d1 mm
(MPa) (MPa) (mm²)
1. 43 (B240) 240 200000 5090.00
2. 115 (B240) 240 200000 5090.00

2.4.- Strength reduction factors

Defined by (Eurocode)
Concrete
gc (Persistent and transient) = 1.50
gc (Accidental) = 1.20
gc (Fire) = 1.00
acc = 1.00
Steel
gs (Persistent and transient) = 1.15
gs (Accidental) = 1.00
gs (Fire) = 1.00

2.5.- Load factors

User values Permanent loads Imposed loads
Anticipated loads 1.35 1.35
FRP Reinforcement failure 1.00 0.50
Fire situation 1.00 0.30
SLS, characteristic 1.00 1.00

3.- FRP STRENGTH

3.1.- Main FRP reinforcement

Simply bonded. SikaWrap® C
Efk tf Width
SikaWrap® 530C - 30cm Fiber type Strength reduction factors efk Number
(MPa) (mm) (mm)
Layer: 1 Carbon gFRP,E: 1.10, gFRP,m: 1.05, gFRP,e: 1.25, gA: 4.00 0.0145 220000.00 0.290 1 300.00
Layer: 2 Carbon gFRP,E: 1.10, gFRP,m: 1.05, gFRP,e: 1.25, gA: 4.00 0.0145 220000.00 0.290 1 300.00
Layer: 3 Carbon gFRP,E: 1.10, gFRP,m: 1.05, gFRP,e: 1.25, gA: 4.00 0.0145 220000.00 0.290 1 300.00

4.- ANTICIPATED COMBINATIONS OF LOADS

4.1.- Initial loads

(Positive) Mi : 1002.00 kN·m

4.2.- Expected loads (strengthening design)

Permanent loads (Positive) MG : 1345.00 kN·m
Imposed loads (Positive) MQ : 1145.00 kN·m

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5.- RESULTS

5.1.- Summary of results

ULS Anticipated loads
loading MEd (kN·m) MRd (kN·m) MRd ³ MEd (NEd = NRd)
Strengthened section
SEd = 1.35 · SG + 1.35 · SQ 3361.50 3571.55
3571.55 kN·m ³ 3361.50 kN·m
ULS Reinforcement failure
loading MEd (kN·m) MRd (kN·m) MRd ³ MEd (NEd = NRd)
Un-strengthened section
SEd = 1.00 · SG + 0.50 · SQ 1917.50 3482.48
3482.48 kN·m ³ 1917.50 kN·m
Serviceability limit states
loading Service stresses
ss ³ 0.8·fyk
SEd = 1.00 · SG + 1.00 · SQ
189.92 MPa ³ 192.00 MPa

Fire resistance (t=0 min.)

loading MEd (kN·m) MRd (kN·m) MRd ³ MEd (NEd = NRd)
Un-strengthened section
SEd = 1.00 · SG + 0.30 · SQ 1688.50 3491.05
3491.05 kN·m ³ 1688.50 kN·m

5.2.- Ultimate limit states

When analysing a cross-section to determine its ultimate moment of resistance, the following assumptions should be
made:
The strain distribution in the concrete in compression and the strains in the reinforcement, whether in tension or
compression, are derived from the assumption that plane sections remain plane and that no longitudinal slip
occurs between or within the components of the section.
The stresses in the concrete in compression are derived from the stress-strain curve in the section 3.1.7 of EN
1992-1-1.
  e  
n

sc  fcd  1   1  c   for 0  ec  ec2

  ec2  

sc  fcd for ec2  ec  ecu2

with
fck
fcd  acc 
gc

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 fcd
ec2 ecu2 n
(MPa)
20.0 0.0020 0.0035 2
The tensile strength of the concrete is ignored.
The stresses in the steel reinforcement are derived from the stress-strain curves in the section 3.2 of EN 1992-1-1.

The strains in the cross-section should take into account the strains present in the existing structure at the time of
application of the FRP reinforcement.
The stresses in the FRP reinforcement are derived from the assumption that the FRP has a linear elastic
characteristic until rupture.
Force balance of section. Initial loads
Mi = 1002.00 kN·m

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 εmax σmax
x

ε = 0.0 ‰

εmin

Maximum and minimum strain emax = 0.12 ‰

emin = -0.39 ‰
Maximum stress in concrete fc = 2.26 MPa
Distance from extreme compression fiber to neutral axis x = 352.67 mm
Stress and strain of reinforcement
Ref. Y Coord. (mm) f (MPa) ε (‰)
No. 12 718 19.84 0.10
A. 5090 -727 -75.51 -0.38
A. 5090 -655 -70.76 -0.35

FRP Reinforcement failure. Minimum combination of loads to be resisted by the un-strengthened member.
SEd = 1.00 · SG + 0.50 · SQ
MRd  MEd 3482.48 kN·m ³ 1917.50 kN·m
MRd : 3482.48 kN·m

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 εmax ε =σmax
3.5 ‰
ε = 2.0 ‰
x

ε = 0.0 ‰

εmin

Maximum and minimum strain emax = 1.38 ‰

emin = -20.51 ‰
Maximum stress in concrete fc = 22.58 MPa
Distance from extreme compression fiber to neutral axis x = 96.89 mm
Stress and strain of reinforcement
Ref. Y Coord. (mm) f (MPa) ε (‰)
No. 12 718 127.62 0.64
A. 5090 -727 -240.00 -19.90
A. 5090 -655 -240.00 -18.88

Strengthened section and expected loads.

SEd = 1.35 · SG + 1.35 · SQ
MRd  MEd 3571.55 kN·m ³ 3361.50 kN·m
MRd : 3571.55 kN·m

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 εmax σmax
x

ε = 0.0 ‰

εmin

Maximum and minimum strain emax = 0.98 ‰

emin = -8.35 ‰
Maximum stress in concrete fc = 14.79 MPa
Distance from extreme compression fiber to neutral axis x = 161.69 mm
Stress and strain of reinforcement
Ref. Y Coord. (mm) f (MPa) ε (‰)
No. 12 718 132.87 0.66
A. 5090 -727 -208.70 -8.09
A. 5090 -655 -208.70 -7.65
FRP -770 -1515.56 -7.96
FRP -770 -1515.87 -7.96
FRP -771 -1516.19 -7.96

Fire situation. Un-strengthened section.

SEd = 1.00 · SG + 0.30 · SQ
MRd  MEd 3491.05 kN·m ³ 1688.50 kN·m
MRd : 3491.05 kN·m

The strength of the un-strengthened member is enough to support the combination of loads corresponding to the fire
situation. The FRP strengthening is therefore not necessary during a fire situation, and does not need to be protected. If
a certain fire rating is necessary, the designer must evaluate the need for a protection of the RC element (concrete and
steel reinforcement) according to the local codes.
5.3.- Serviceability limit states
SLS stresses in the steel reinforcement at the characteristic combination of actions should not exceed the relevant
design limits in Eurocode 2, part 1-1.

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Force balance of section. SLS Characteristic combination of loads
SEd = 1.00 · SG + 1.00 · SQ

εmax σmax
x

ε = 0.0 ‰

εmin

Maximum and minimum strain emax = 0.44 ‰

emin = -0.99 ‰
Maximum stress in concrete fc = 4.23 MPa
Distance from extreme compression fiber to neutral axis x = 473.64 mm
Stress and strain of reinforcement
Ref. Y Coord. (mm) f (MPa) ε (‰)
No. 12 718 78.25 0.39
A. 5090 -727 -189.92 -0.95
A. 5090 -655 -176.56 -0.88
FRP -770 -132.96 -0.60
FRP -770 -133.00 -0.60
FRP -771 -133.04 -0.60

In the case of significant non-static live loads during the hardening of the adhesive, the reduced adhesive strength
cannot be determined according to tabulated data as indicated in TR55, 6.9.4, considering that the acting loads during
that period correspond to the quasi-permanent load combination.
efe,curing = 0.000289 > 0.000200
5.4.- Additional check
In addition, if the ultimate moment of resistance is less than 1.15 times the required value, the section should be
proportioned such that the strain at the centroid of the tensile steel reinforcement is not less than 0.002 + fyk/(Esgs).
fyk
MRd  1,15  MEd ; es  0,002  0.00809 ³ 0.00304
Es · g s

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5.5.- FRP arrangement
The previous results correspond to the following FRP scheme:
FRP main reinforcement: Number of layers: 3, 1 + 1 + 1 (SikaWrap® 530C - 30cm)

6.- PRODUCT SPECIFICATION

6.1.- Bonded SikaWrap® fabrics

The strengthening shall be achieved using unidirectional carbon fibre fabric, impregnated and externally bonded to the
structure with epoxy adhesive Sikadur®-300

The material shall be a pultruded, unidirectional CFRP plate, and exhibit a fibre volume content >68%.

The fibers should be aligned and free of torsion.

The material shall have a long track record (> 25 years) for structural strengthening.

The fibre fabric shall be unidirectional and fabricated of PAN based carbon fibres.

Installation in several layers shall be possible.

The material shall have a long track record for structural strengthening.

Measured values of mechanical properties of laminated fabrics shall be provided, minimum test series of 20 samples.

6.1.1.- Concrete surface preparation

Any unsound material shall be removed and removed concrete shall be repaired as described above. Large blowholes
and honeycombing shall be filled with a suitable repair mortar.

Repair materials shall be fully compatible with the adhesive.

The actual strength of the concrete substrate shall be verified with at least three pull-off tests.

The concrete shall be older than 28 days.

The laitance layer on the substrate surface shall be removed and an open-textured surface shall be created.

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The substrate surface shall be cleaned so that it is free from oil, grease and any other contaminants as well as loose
particles and dust.

For fibre fabric application, all corners shall be rounded to a minimum radius of 20 mm and any sharp edges shall be
removed.

The substrate moisture content shall be less than 4% pbw.

6.1.2.- SikaWrap® fabrics

The materials shall comply with the performance characteristics described as follows:

6.1.2.1.- Typical Properties of SikaWrap® 530C - 30cm fabric:

Typical dry fiber properties:

E-Modulus EN 2561/ASTM D3039 » 230000 N/mm² (MPa)

Tensile Strength EN 2561/ASTM D3039 » 4000 N/mm² (MPa)
Strain at break EN 2561/ASTM D3039 1.7 %

Typical laminate properties (related to fibre thickness):

E-Modulus EN 2561/ASTM D3039 » 225000 N/mm² (MPa)

6.1.3.- Epoxy Adhesive

The adhesive shall be epoxy based.

The SikaWrap® 530C - 30cm fabric shall be impregnated with resin before placement on the structure with Sikadur-300

6.1.3.1.- Typical Properties of Sikadur®-300 adhesive

The adhesive must comply with EN 1504-4.

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 Chemical base Epoxy resin
Density 1.16 kg/l (at +23°C).
+15ºC » 2000 mPas
Viscosity (shear rate 50/S) +23ºC » 700 mPas
+40ºC » 200 mPas
Thermal expansion coefficient -20ºC to +40ºC 6.0 x 10-5 per °C
Curing
7 days, +15ºC +43ºC
Thermal stability. HDT (ASTM D648) 7 days, +23ºC +49ºC
3 days, +40ºC +60ºC
7 days, +40ºC +66ºC
Service temperature 23ºC Curing -40ºC to +45ºC
Tensile Strength DIN EN ISO 527-3 45 N/mm2 (7 days at +23°C)
Bond Strength (sandblasted substrate) DIN EN ISO 4624 Concrete fracture (> 4 N/mm²)
E-Modulus (flexural) DIN EN 1465 2800 N/mm2 (7 days at +23°C)
E-modulus in tensile DIN EN ISO 527-3 3500 N/mm2 (7 days at +23°C)
Elongation at break DIN EN ISO 527-3 1.5% (7 days at +23°C)

6.1.4.- Application procedure

The wrap shall be cut to size with special fibre scissors.

A primer layer of the impregnating resin shall be applied on the substrate surface, using a toothed trowel or a roller.

Distribute 2/3 of the expected Sikadur®-300 quantity on a clean PE sheet and then place the pre-cut fabric onto the resin
covered sheet. Saturate SikaWrap® fabric by rolling with a mohair or plastic roller in the fibre direction until the resin
penetrates through the fabric. Distribute the remaining 1/3 of the Sikadur®-300 onto the fabric and evenly spread with
roller to fully saturate fabric. Remove the excess of resin.

The fabric shall be placed on the substrate, pressed on gently, and the resin shall be worked into the fabric with an
impregnation roller until the fabric is completely saturated.

Additional layers shall be installed as described above, preferably wet-on-wet.

In case of a cementitious overcoat, the resulting resin surface shall be broadcasted with quartz sand.

Impregnation shall always be performed in fibre direction.

After application, the finished fibre fabric installation of shall be protected from rain, sand, dust and any other
contaminants.

If necessary, the applied system shall be protected with a suitable coating (compatibility tests between the coating and
the fabric shall be available).

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7.- LEGAL DISCLAIMER
THIS SOFTWARE APPLICATION AND THE RESULTS DERIVED FROM ITS UTILIZATION ARE INTENDED ONLY FOR USE BY
PROFESSIONAL USERS WITH EXPERT KNOWLEDGE IN THE AREA OF THE INTENDED APPLICATION. USERS MUST
INDEPENDENTLY VERIFY THE RESULTS BEFORE ANY USE AND TAKE INTO ACCOUNT THE SITE AND APPLICATION
CONDITIONS, PRODUCT DATA SHEET AND PRODUCT LITERATURE, TECHNICAL STATE OF THE ART AS WELL AS LOCAL
APPLICABLE STANDARDS AND REGULATIONS.

With respect to the software application and results derived from its use, SIKA MAKES NO WARRANTIES OF ACCURACY,
RELIABILITY, COMPLETENESS, MERCHANTABILITY OR FITNESS FOR ANY PURPOSE. THE SOFTWARE APPLICATION IS
PROVIDED ON AN "AS-IS" BASIS AND SIKA EXPRESSLY DISCLAIMS ANY WARRANTIES WITH RESPECT TO THE SOFTWARE
APPLICATION AND RESULTS DERIVED FROM ITS USE.

Sika shall not be liable for any consequential, punitive, incidental, exemplary, or special damages (including but not
limited to loss of business opportunity or loss of profit) arising out of the evaluation or use of the software application
and results derived from its use.

The information, and, in particular, the recommendations relating to the application and end-use of Sika products, are
given in good faith based on Sika's current knowledge and experience of the products when properly stored, handled
and applied under normal conditions in accordance with Sika’s recommendations. In practice, the differences in
materials, substrates and actual site conditions are such that no warranty in respect of merchantability or of fitness for a
particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this
information, or from any written recommendations, or from any other advice offered. The user of the product must test
the product’s suitability for the intended application and purpose. Sika reserves the right to change the properties of its
products. The proprietary rights of third parties must be observed. All orders are accepted subject to our current terms
of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product
concerned, copies of which will be supplied on request.

Except as indicated otherwise, all information, text, graphic images, features, functions, and layout contained in this
software are the exclusive property of Sika and may not be copied or distributed, in whole or in part, without the
Company's express written consent.

By transmitting information to Sika, you grant to the Company the unrestricted irrevocable license to use, reproduce,
display, modify, distribute and perform such information. Personal identity information is used by Sika only to process a
request for information by you or for marketing our products and services.

© Copyright Sika Services AG 2016

8.- ABOUT SIKA® CARBODUR® CALCULATION SOFTWARE

Engineered by:

Cype Software - Eusebio Sempere, 5 - 03003 Alicante (Spain)

www.cype.com

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