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FAQ - Frequently Asked Questions: Verdasio M-Redistribution
FAQ - Frequently Asked Questions: Verdasio M-Redistribution
• UV degradation • 1985
• Fire • CE = Aero
• C fiber production • Reliability
• Pultrusion, FOS • C-Wrapping
• Equivalent modulus
• Lightning strike
• Stress Corr E-glass
• Poles, New Construc
• Application u Traffic
• Gradient anchorage
• Decision matrix
• Basics straps • Verdasio
• Puck’s GFRP Girder • M-Redistribution
Does Ultraviolet (UV) light harm CFRP?
UV attacks the
polymer matrix,
Degraded polymer
matrix
UV, wind and rain degradation
Surface of UD-
CFRP after 10 years
of outdoor
weathering in
Zurich
(sand blasting in a
dessert !)
UV, wind and rain degradation
5 μm
….even so we protect in general exposed
CFRP surfaces, especially stay cables
with polyethylene
hoses highly filled
with carbon black
or
with pipes made of
the same material
….flat surfaces like strips, wet lay-up can be
protected by paint. Since 1991 exposed!
AQUAVERN Primer,
50 µm
LUXORAL, 40 µm
ETOKAT Primer, 60
µm
NUVOVERN, 40 µm
CFRP strip after 18 years of 45° south
exposure
50 mm wide
CFRP strip after 18 years under the
soffit of Ibach Bridge near Lucerne
50 mm wide
UV, wind and rain degradation
Conclusions:
• no real problem, even if not protected
• most post-strengthening application are
not exposed (soffit, inside box etc.)
• stay cables need pipes or hoses also due
to aerodynamic reasons
Replica Technique
Wet a strip of
cellulose acetate
replicating tape
with acetone
and apply it to
the CFRP strip.
Replica Technique
Apply light
Pressure.
Replica Technique
After it dries
completely, strip it
from the substrate,
turn the replica over
and tape it to a glass
slide. Afterwards
sputter the replicas
with gold and
examine it by a
SEM.
Replica Technique
Most polymer
matrices burn at
elevated
temperatures.
Does fire harm CFRP?
nice, glossy
polymer surface
Does fire harm CFRP?
1200
Temperature [°C]
1000
800
600
400
200
0
0 20 40 60 80 100
Duration [min]
Does fire harm CFRP?
5 μm
5 μm
g = 3 kN/m
Mmax = 71 kNm
V = 51 kN
V = 55 kN
Adhesives
Girders #1 to #5:
Epoxy based Sikadur 30 S-02,
curing at 20°C; Tg = 45°C
Examples of tested girders
∆𝜹𝜹
= 𝟏𝟏𝟏𝟏. 𝟑𝟑 𝒎𝒎𝒎𝒎/𝒎𝒎𝒎𝒎𝒎𝒎
∆𝒕𝒕
After 45 minutes of fire and static
loading
After 70 minutes of fire and static
loading
Time to failure [min]
Thomas Edison
Patent vom Fort Myers, Florida
27. Januar 1880
Since 1963 fibers for structural
applications
t Royal Aircraft
Establishment
(RAE),
Farnborough,
England
1st step
PAN - filament exhaust chemical
cyclization,
catalyst cross linking
and stretching
air
T = 200-300 °C
T = 200-220 °C T = 220-300 °C
t = 10-30 min t = 30-100 min
Production of fibers
2nd step
exhaust
thermal degradation
in inert gas
exhaust gas
3rd step
graphitization
t = 5-30 min
in Argon
Argon
T = 2500° - 3000°C
semi finished
products
Carbon fibers
C-Fiber
Hair
Ladder structure of carbon fibers
approx. 100 GPa
0.246 nm
0.1415 nm
Bonds in a Graphite Lattice
Graphite structure of pencil
primary bonds
0.246 nm
with each pencil line
one layer ! 0.1415 nm
Mechanical properties of C-fiber
Toray T700S
Tensile strength (longitudinal) 4900 MPa
Elastic modulus E (longitudinal) 230 GPa
Strain at failure 2.1 %
3
Density 1.8 g/cm
−6
Thermal expansion (longitudinal) 0.1x10 m/m/°C
Price forecast made 1977
Price forecast made by
EMPA in 1977 published
in "aktuelles bauen"
6/1977, page 74:
14’500 RMB / kg
115 RMB / kg
This forecast was the
basis for EMPA to go into
R&D about CFRP in
construction!
Development of prices 1994 - 2008
2008 = 125%
1998 = 134%
1993 = 100%
Carbon fiber
of a carbon fiber is:
?
A 18 km
B 120 km
C 220 km
D 385 km
Answer Quiz
Carbon fiber
385 km
of a carbon fiber is:
A 18 km (HS steel)
B 120 km (E-glass)
C 220 km (Aramid; Kevlar)
D 385 km (Carbon)
Pultrusion (production of wires & strips
with thermo set matrix systems)
0.20
0.15
Strain [%]
0.10
0.05
0
0 2 4 6 8 10 12 14 16 18 20
Time [min]
Temperature monitoring
Bridge over the "Kleine Emme“
1998
Cross section
View
Bridge over the Kleine Emme
Sustained stress 1350 MPa
Problem:
• CFRP is relatively resistive to electricity
• this causes CFRP to heat up as the current
passes through it
• CFRP becomes so hot that the polymer
matrix vaporizes
Are lightning strikes a problem?
Solution:
• Aircraft industry developed aluminum
grids which are used to protect the
composite in its outermost layers.
• In the case of the Stork Bridge it was
decided to insulate the CFRP parallel wire
bundles with very little additional cost.
Lightning strike screen
Prepreg with
woven fabric of
aluminum
Are lightning strikes a problem?
until now:
30 meters
12 tones
CFRP concrete power poles
The mould is going to be closed
new versus classical
5.8 t
12 t
20
15
10
Experiment
5
Calculation
0
0 200 400 600 800 1000 1200
Deflection at the tip [mm]
Made with Pre-tensioned CFRP
10 km CFRP wires
therefore
Load Transfer Media
delamination and pullout
creep resistend
→ high modulus
therefore
shear peak
Which load transfer media (LTM)?
F F
Concept of anchorage socket
relative displacement
Desired radial pressure
relative displacement
Danger of creep failure (pull-out)
relative displacement
Laminated CFRP
strap
Pin Loaded, laminated CFRP Strap
σ// σ⊥ τ//⊥
Dr. A. Winistörfer
Relative strength vs. radii Werne 1
Werne 2
ro 0.80
Werne 3
0.70 US-Army
0.60 Oser 1
ri 0.50 Oser 2
σf / σUTS
0.40 Winistoerfer
0.30
0.20
0.10
0.00
1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 1.80
σc σc ro / r i
Answer: very thin laminate (0.12 mm)
σ// σ⊥ τ//⊥
non-laminated
laminated
Verification
F
white
marks
1.4
1.2
1
Strain [%]
Layer 10
0.8 Layer 6
Layer 4
0.6
Layer 2
0.4 Layer 1
0.2
0
0 5 10 15 20 25 30
Load [kN]
3 MN Unit
A. Winistörfer
Efficiency
300
250
200
Capacity [kN]
150
100
50
0
1 10 20 30 40 50 60 70
Number of layers [N]
Production by tape laying machine
up to 48 m
Creep experiments
0.10
0.08
80 % von UTS
0.04
0.02
0.00
0 100 200 300 400 500 600 700
Time [h]
Creep experiments
Creep experiments
built in 1912
strengthened: 1980
photo taken: 2006
Strengthening with CFRP
• CFRP not
known in CE
community
• (if known,
absolutely
not
accepted)
today yesterday today
• CFRP in
most parts
of the world
for
rehabilitation
well known
and highly
Presenta accepted
From JEC 2009 in Paris Air- & Spacecraft
Industry
Construction
Industry
Sport
Industry
Cube 12.732 km
long
distance distance
= 1 mm (Volume) = 12 m
10 µm
10 mm
Verified on E-glass fiber
Reliability: solid graphite vs. CFRP
Cross section
of RC column
Increase of confinement
by CFRP wrapping for
circular columns: state
uniform of the art!
confinement
CFRP wrapping of rectangular columns
6 cm
Active column wrapping
woven fabric
pressure hoses
40 cm
Active column wrapping
wrapping of 0.12 mm
thick CFRP-tape
Active column wrapping
injecting polymer mortar
with high pressure
Active column wrapping
injecting polymer mortar
with high pressure
Active column wrapping
injecting polymer mortar
with high pressure
“octagon”
Active column wrapping
12 mm
pre-stressed by 2
hoses at each
Enormous gain on column side)
“systems ductility”, even Maximum Load:
when all single 3713 kN
components are brittle Maximum
materials! displacement: -
63.8 mm (at
failure)
Deformation under compression [mm]
Equivalent modulus (example one stay cable)
Steel CFRP
Steel CFRP
Relative equivalent modulus Ee
equivalent
Modulus
Ee 1
=
E (ρ l) 2
1+ E
12 σ 3
Relative equivalent modulus Ee
Ee 1
=
E (ρ l) 2
1+ E
12 σ 3
Modulus
Relative equivalent modulus Ee
Ee 1
=
E (ρ l) 2
1+ E
12 σ 3
Density
Relative equivalent modulus Ee
Ee 1
=
E (ρ l) 2
1+ E
12 σ 3
Working
stress
Relative equivalent modulus Ee
Horizontal
span
Ee 1
=
E (ρ l) 2
1+ E
12 σ 3
1.0
800MPa
0.9 600MPa
30% loss 400MPa
0.8 for steel
0.7
800MPa
0.6
Ee/E
0.5
600MPa
0.4 200MPa
0.3
0.2 400MPa
0.1
200MPa
0.0 horizontal
0 500 1000 1500 2000 cable span [m]
Additional stiffness for long stays
540m
Russkystay
Hybrid Bridge (Wladiwostok)
cable
arrangement for
long span bridges?
552 m
Stress corrosion (static fatigue) of
E-Glass
5% decay of strength per decade
75% .19
70% 1.9
65% 19
60% 190
Stress corrosion of E-Glass
5% decay of strength per decade of time
120
relative stress [%]
100
70%
80
3.8 a
60
40 60%
20 190 a
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
log t [min]
Application of CFRP under traffic
conditions
Fast curing "under traffic"
200
Load F [kN]
no vibration/reg
curing
0
0 10 20 30 40 50 60 70 80 90 100
Deflection [mm]
Fast curing "under traffic"
200
Load F [kN]
no vibration/reg
curing
vibration/reg curing
0
0 10 20 30 40 50 60 70 80 90 100
Deflection [mm]
Fast curing "under traffic"
200
Load F [kN]
no vibration/reg
curing
vibration/reg curing
vibration/ 2h curing
at 80°C
0
0 10 20 30 40 50 60 70 80 90 100
Deflection [mm]
Which High Performance Fiber?
• Carbon
• Glass
• Aramide (Kevlar)
• Basalt
Criteria “Fatigue”
• Carbon
• Glass
• Aramid (Kevlar)
• Basalt
Criteria “Strength”
• Carbon
• Glass
• Aramide (Kevlar)
• Basalt
Criteria “E-Modulus”
• Carbon
• Glass
• Aramide (Kevlar)
• Basalt
Criteria “Stress Corrosion”
• Carbon
• Glass
• Aramide (Kevlar)
• Basalt
Criteria “Alkaline Resistance”
• Carbon
• Glass
• Aramide (Kevlar)
• Basalt
Criteria “Cost”
• Carbon
• Glass
• Aramide (Kevlar)
• Basalt
Tailormade “ Decision Matrix” needed!
Flanges: unidirectional
Concept of GFRP Box Girder
Web: ±45°
Concept of GFRP Box Girder
Concept of GFRP Box Girder
unidirectional Flange
Shaft of Filament Winding Machine
(cross section)
Foam
core
as
lost
mold
Winding
of the
inner
±45°
layers
for
the web
Add the
first
unidirec-
tional
flange
Add the
second
unidirec-
tional
flange
Winding
of the
outer
±45°
layers
for
the web
188 mm
Resulting
cross
section
118 mm
Cross section
(Detail)
critical
load
transfer
region
shifted
direction
neutral
axis
top flange
4
GFK-Kastenträger 1
Girder No. 5
100 million cycles with 2.0 Hz (1.6 years)
Fmin= 10 kN per loading point
Fmax= 40 kN per loading point (= 20% Fu )
Girder No. 6
100 million cycles with 2.0 Hz (1.6 years)
Fmin= 10 kN per loading point
Fmax= 60 kN per loading point (= 30% Fu )
Fatigue
Girder No. 6
100 million cycles with 2.0 Hz (1.6 years)
Fmin= 10 kN per loading point
Fmax= 60 kN per loading point (= 30% Fu )
Girder No. 5b
47 million cycles with 1.0 Hz (2 years)
Fmin= 10 kN per loading point
Fmax= 80 kN per loading point (= 40% Fu )
60 kN
lead 60 kN
lead
Deflection over the Whole Span
36.5
Deflection [mm]
36.0
35.5
35.0
34.5
34.0
20 years
33.5 3.7 mm creep deformation
33.0 = 1.3/1000 of the span
32.5
32.0
0 50000 100000 150000 200000
Time [h]
Experimental vs Calculated Deflections
F=50 kN F=50 kN
-5
calculated
-10
-15
-20
experimental
-25
-30 34.1
-35
-40 35.9
Conclusion
post-tensioned RC
Verdasio Bridge
4 CFRP cables
8 Steel: experiment
7 since 1958
6
5
4
3
2
1 CFRP: experiment
0 since 1998
0 2 4 6 No stress relaxation!
log t [h]
Verdasio Bridge
8m 8m
Bending-Moment
Redistribution
Continuous 2-span
girder post-tensioned
with CFRP cables
F
elastic hinges
Bending-Moment Redistribution