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Fiber Reinforced Polymer (FRP) Portable Bridge: Modeling and Simulation

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European Journal of Scientific Research
ISSN 1450-216X Vol.44 No.3 (2010), pp.437-448
© EuroJournals Publishing, Inc. 2010
http://www.eurojournals.com/ejsr.htm

Fiber Reinforced Polymer (FRP) Portable Bridge:

Modeling and Simulation

Norazman Mohamad Nor

Faculty of Engineering, Universiti Pertahanan Nasional Malaysia
Kem Sg. Besi, 57000 Kuala Lumpur, Malaysia
E-mail: azman@upnm.edu.my
Tel: +603-90514467; Fax: +603-90513472

Vivekananthan Devarase
Faculty of Engineering, Universiti Pertahanan Nasional Malaysia
Kem Sg. Besi, 57000 Kuala Lumpur, Malaysia

Muhamad Azani Yahya

Faculty of Engineering, Universiti Pertahanan Nasional Malaysia
Kem Sg. Besi, 57000 Kuala Lumpur, Malaysia

Suriyadi Sojipto
Faculty of Engineering, Universiti Pertahanan Nasional Malaysia
Kem Sg. Besi, 57000 Kuala Lumpur, Malaysia

Siti Khadijah Che Osmi

Faculty of Engineering, Universiti Pertahanan Nasional Malaysia
Kem Sg. Besi, 57000 Kuala Lumpur, Malaysia

Abstract

This paper investigates the performance of Fiber Reinforced Polymer (FRP)

portable bridge using modeling and simulating analysis. Portable bridge is an essential
asset for defense and disaster relief operations. In the early days, military bridges were
made from steel, other than concrete, causing the weight of the bridge to be large, thus,
need more vehicles to transport the bridge and crane with higher capacity to erect it.
Subsequently, it will cost more to operate. To overcome these problems, aluminum and
metal alloy were introduced to reduce the weight of such structure. However, on the other
cases, since composite materials such as Fiber Reinforced Polymer (FRP) was emerged as
a lightweight material, and therefore, it is being considered to be used as a primary material
for the portable bridge. The FRP has high strength to weight ratio, thus making its product
is lighter than steel and other alloy. Alternatively, for this study, MSC Nastran FEA
software is selected to simulate the proposed design model bridge. The simulation is
actually focusing on the entire structural elements of the bridge, especially to the main
beam whereby serving as the important structure of the portable bridge. Conceptually, the
proposed model of the portable bridge is designed with anticipated length of 46 meters is
analyzed by using the telescopic concept. Shortly, through the sequence of the study, FRP
is found as the best material for the portable bridge. Conversely, after conducting the
Fiber Reinforced Polymer (FRP) Portable Bridge:
Modeling and Simulation 438

simulation analysis, the bridge is proven can accommodate the load safely when a main
battle tank load is applied on it.

Keywords: Portable Bridge, FRP, Modeling, Simulation, FEA

1. Introduction
Bridges are man-made structures constructed to go across any obstacle, for instance, river, lake, or
valley. Generally, a bridge is constructed to connect between two points, home-bank and far-bank. The
bridge must be designed in such a way that it can bear the load transverse on it. The bridge also must
comply with the required safety aspect and related design code. Besides that, the bridge should be able
to resist the natural forces such as wind load, weathering and vibration resistant. A bridge is normally
constructed using material such as wood, steel, concrete and also composite material. In this research,
Fiber - Reinforced Polymer (FRP) is being considered as the main material for the bridge. FRP has
several favorable properties, such as high strength to weight ratio, corrosion-free characteristics, high
degree of free formability and good fatigue resistance, hence make this type of material as a target
material for the construction of portable bridges. In advance, the previous research shows hundreds of
pedestrian and several vehicular FRP bridges have been built and proving that the feasibility of this
material is actually suitable for lightweight bridges (Sedlacek et al. 2004; Keller 2002; Weaver 1997;
Johansen et al. 1992; Johansen et al. 1996; Wight et al. 2006).
In the military, bridges are the crucial asset to survival when it comes to assisting the mobility
of forces. For example, bridge is urgently needed at war for military forces and vehicle to cross
obstruction such as lake and river. Portable bridges also needed to replace any damaged bridge or
bridge destroyed by enemy forces. In this kind of situation, normally a portable bridge system is used
to ensure the mobility of forces without further delay. On the other hand, international non-government
organizations (NGO’s) have an intense interest in cross-country mobility where infrastructure may
have been badly damaged by various incidents, conflict or natural disaster (Wight et al. 2003; Wight et
al. 2002). There are various portable bridges being used by many countries world-wide. The design
process is basically to determine the appropriate type of materials and size of structural elements, to
include design of the connections (joints), and also to ensure the bridge can serve it purposes safely.

2. Objective
The main objectives of this study are as follows:
i. To identify the best material to be used for military bridges focusing on composite material;
ii. To model the bridge using CAD (Computer aided engineering software); and
iii. To simulate the model, analyze the effect of the load and recommend some improvement.

3. Literature Study
3.1. Portable Bridge
Portable bridges are efficiently used as temporary structure to the armed forces. The main purpose is to
enhance mobility of forces, i.e. to cross obstacles such as river, lake, valley or cliff. Instead, portable
bridge could also be used for the domestic purpose such as to provide temporary access to the public in
disaster area, when existing land line of communication is damaged or destroyed. Currently, various
types of portable bridges are being used throughout the world. Many developed countries worldwide
have produced various types of portable bridges that have its own uniqueness and advantages. Portable
bridges are built according to the design influenced by types of utilization and the fundamental needs.
439 Norazman Mohamad Nor, Vivekananthan Devarase
Muhamad Azani Yahya, Suriyadi Sojipto
Siti Khadijah Che Osmi

The fundamental needs are such as to launch an attack, mobilization during operation, or logistic
support.
The bearing load for portable bridges is measured by referring to the Military Load Class
(MLC). MLC is a classification system for the military bridge capacity. It is also a safety load limit that
can be catered by a particular bridge (Brassey’s, 1998). There are several types of portable bridges that
commonly used by respective armed forces throughout the world which are listed below:
i. PTA Modular Assault Bridge
ii. LEGUAN Bridgelayer
iii. PAR 70 Support Bridge
iv. Panzerschnellbrucke 2 (PSB 2)
v. Class 30 Medium Assault Bridge (MAB)
vi. PFM Floating Bridge

3.2. Composite Material: Fiber Reinforced Polymer (FRP)

Fiber Reinforced Polymer (FRP) composites are defined as a polymer (plastic) matrix, either thermo
set or thermoplastic, and is reinforced (combined) with a fiber or other reinforcing material with a
sufficient aspect ratio (length to thickness) to provide a discernable reinforcing function in one or more
directions.
FRP composites have brought many benefits to their selection and use. The selection of the
materials depends on the performance and intended use of the product. The composite’s designer can
tailor the performance of the end product with the proper selection of materials. It is important for the
end-user to understand the application environment, load performance and durability requirements of
the product and convey this information to the composite’s professional industries. In short, previous
researchers have summarized several benefits of the composite materials which are listed as follows
(Khairulfitri, 2004; Natalie, 2007; Nordiana 2005):
i. Lightweight
ii. High strength-to-weight ratio
iii. Directional strength
iv. Corrosion resistance
v. Weather resistance
vi. Dimensional stability
vii. Radar transparency
viii. Non-magnetic
ix. High impact strength
x. Low maintenance
xi. Long term durability
xii. Small to large part geometry possible
xiii. Tailored surface finish
Basically, the primary functions of the resin are to transfer stress between the reinforcing fibers,
act as a glue to hold the fibers together, and protect the fibers from mechanical and environmental
damage. Resins are divided into two major groups known as thermo set and thermoplastic.
Thermoplastic resins become soft when heated, and may be shaped or molded while in a heated semi-
fluid state and become rigid when cooled. Thermo set resins, on the other hand, are usually liquids or
low melting point solids in their initial form. When it is used to produce finished goods, these
thermosetting resins are “cured” by the use of a catalyst, heat or a combination of the two. The most
common thermosetting resins used in the composites industry are unsaturated polyesters, epoxies, vinyl
esters and phenolics.
Fiber Reinforced Polymer (FRP) Portable Bridge:
Modeling and Simulation 440

Meanwhile, fibers or reinforcements which used to carry loads along the length of the fiber will
provide strength and stiffness in one direction. Reinforcements are oriented to provide tailored
properties in the direction of the loads imparted on the end product. Reinforcements can be both
natural and man-made. The most commonly used fibers are Glass fiber, Carbon fiber and Aramid fiber.
A wide variety of additives used in composites helps to modify the material properties and
tailor the laminate’s performance. Although these materials are generally used in relatively low
quantity by weight compared to resins, reinforcements and fillers, and also performs critical functions.
Additives and modifier ingredients can expand the usefulness of polymers, enhance their process
ability or extend product durability. Apart from that, additives and modifiers often increase the cost of
the basic material system, but at the same time, these materials always improve cost/performance.

4. FRP Portable Bridge Design

4.1. Research Design
The components of the portable bridge are designed and consist of a set of several main beams, a deck,
bracing frame, and ramp and also proposed reinforced cable system. There are three sets of main
beams and each of them has five different elements with various sizes. This bridge uses the telescopic
concept whereby each of the smaller elements will be inserted into the bigger element. Conceptually,
the purpose of this concept is to save the require space. The primary task of the main beam is to
support the imposed load on the bridge. In addition, the actual function of the deck is to provide a
passage for vehicle to travel. Figure 1 to Figure 4 shows the illustrations of the conceptual bridge.
Figure 1: Isometric View of the Bridge Structure

Figure 2: Reinforced Cable System at the End of the Beam

Figure 3: Elevation View of the Bridge Structure.

First Second Third Fourth Fifth

Elemen Element Element Element Element
441 Norazman Mohamad Nor, Vivekananthan Devarase
Muhamad Azani Yahya, Suriyadi Sojipto
Siti Khadijah Che Osmi

Figure 4: Cross Section View of Bracing Frame

Bracing frame

Main beams

4.2. Imposed Load

The imposed load that will be used for the simulation is the weight of the heaviest main battle tank
currently available in Malaysia. PT-91M Twardy is the heaviest tank owned by ATM is manufactured
in Poland. The projected weight of this particular tank is 45.5 tons.

Weight of Tank = 45.5 Tons

Weight of Tank in Kg = 45.5 x 1000
= 45500 Kg
Weight of Tank in Newton = 45500 x 9.81
= 446355 N
Imposed Load = 446355 N x safety factor

4.3. FRP Material

The most appropriate material for the portable bridge is T300/5208 Carbon/Epoxy Unidirectional
Prepreg. Principally, this particular carbon composite material consists of the T300 Carbon Fiber and
5208 epoxy matrix. The material is selected after conducting a detail research and also comparing with
the other possible choice such as glass fiber. Generally, carbon fiber has a very high strength compare
to the other fibers and making it as the most desired reinforcement. The T300/5208 Carbon/Epoxy
Unidirectional Prepreg comprises 70 percent of Carbon Fiber and the remaining of 30 percent comprise
with epoxy matrix composition. The higher percentage of Carbon Fiber in the composite material
contributes to its strength and also its ability to resist the normal impact.
Besides, the carbon composite has high modulus of elasticity making it as the first choice for
the bridge. The higher the modulus of elasticity, thus the lesser material will deflect. This characteristic
is essential to ensure that the bridge will not deflect too much. Unfortunately, brittle feature is one of
the disadvantages of this material because it has a tendency to break or crack when it deflects a lot due
to accommodating heavy load. Therefore, a higher modulus of elasticity is needed to counter this
problem.
The Carbon fiber for the T300/5208 Carbon/Epoxy assigns the 0 degree (Axial) unidirectional
for the material orientation. This orientation is chosen in order to enable the structure to resist
longitudinal bending, axial tension and compression. In other words, this may enhance the stiffness of
the bridge and therefore, reduce the deflection rate and also counter fatigue infliction.

5. Modeling and Simulation

Modeling is the representation of a system or part of that in a psychical or mathematical form that is
suitable for demonstrating the behavior of the system. The purpose of simulation is to subject models
to various inputs or environmental condition to observe how they behave and thus, explore the nature
Fiber Reinforced Polymer (FRP) Portable Bridge:
Modeling and Simulation 442

of the result that might be obtained from the actual world system. Simulation involves the modeling of
a difficult situation into a simpler and more convenient form that can be studied by isolating without
the troublesome complex side effects usually accompany a real engineering situation.
The MSC software of Finite Element Analysis (FEA) or commonly known as Finite Element
Method (FEM) is used to simulate the FRP Portable Bridge. The basic material properties needed to
run the simulation are as follows:
i. Elastic Modulus, E = 181 GPa
ii. Poisson’s ratio = 0.28
iii. Density = 1.9 g/cm3

5.1. Bridge Modeling

Geometry modeling unambiguously describes three dimensional shape of the object. It is able to
distinguish between the inside and outside of the object, and able to support the calculation of mass
properties such as weight and moment inertia. The three dimensional shape is conveyed with
orthographic projections and this is better than a hand drawn portrayal. The advantage is in the ability
to make easy drawing modification.
A three dimensional wireframe modeling adds little additional information. The surfaces
between the wire frame edges are not defined and the computer is not able to determine what is inside
or outside of the project being drawn. Wireframe models often are confusing and difficult to interpret
because of extraneous lines. The figures below illustrate the wireframe model of the portable bridge by
using FEA CAD software.
The figures below represent a geometry model (Figure 5) of the entire bridge model by
Solidworks CAD software and wireframe model (Figure 6) of the portable bridge by using FEA
software.

Figure 5: Geometry modeling Figure 6: Wireframe model

5.2. Finite Element Analysis

Multiple analyses have been done in order to obtain the most accurate and best result for the portable
bridge. Eventually, a few selected analyses are considered as relevant and significant to the project. All
together there are 4 categories of analysis was presented in order to see how the bridge responses to the
imposed load. The stress and the corresponding deflection of the bridge are acquired through the
simulation which helps to observe the result obtained.
Generally, there are 5 different locations of single loading and one location for double loading
on the bridge whereby at these locations the load will be inserted on the plate of the bridge. The
purpose of the plate is to represent as the dimension of the tank and to distribute the load evenly to the
main structure. All the six different locations are shown on Figure 7 to Figure 12 below.
443 Norazman Mohamad Nor, Vivekananthan Devarase
Muhamad Azani Yahya, Suriyadi Sojipto
Siti Khadijah Che Osmi

Figure 7: First loading position Figure 8: Second loading position

Figure 9: Third (Center) loading position Figure 10: Fourth loading position

Figure 11: Fifth loading position Figure 12: Double loading position

There are 4 categories of simulations were examined and are listed as follows:
i. Tank load at the center location analysis.
ii. Tank load for 5 different positions with 1000 kN force cable analysis.
iii. 1000 kN force cables only (no load is applied).
iv. Double of tank load with 1000 kN force cable analysis.

5.2.1. Tank Load at the Third (Center) Location Analysis

The tank load is imposed at the center of the portable bridge. The Figure 13 and Figure 14 below
indicate the stress and the deflection of the portable bridge due to the imposed tank load.

Figure 13: Stress result diagram for tank load at Figure 14: Deflection result diagram for tank load at
center position center
Fiber Reinforced Polymer (FRP) Portable Bridge:
Modeling and Simulation 444

From figures above, it is clearly illustrate that the highest deflection is at the mid span of the
bridge with a displacement of 435 mm as the maximum deflection of the bridge. Although the stress
endured by the bridge is still half of its limit but the deflection can be considered excessive and not
suitable to be utilized. The maximum stress caused by the loads on the bridge is 1.13x107 Pa @ 1330
MPa.

5.2.2. Tank Load for 5 Different Positions with 1000 kN Cable Force Analysis
To overcome the problem of deflection, cables will be used with tensile force applied to it. The cable
tensile force will deflect the bridge upward to a certain displacement. The proposed tensile force
intensity is 1000 kN on each cable. From the results obtained (Figure 15 to Figure 24), it shows that the
cable with 1000 kN is sufficient to accommodate the tank load and subsequently reduce the deflection.
Due to the cables tensile force the bridge is deflected upwards with a maximum deflection of 1013
mm. The bridge still deflected upward even after loaded with the imposed load, and the minimum
upward deflection is 324 mm.
The analysis also revealed that the cable trusses deflected at the maximum level and thus
subjected to failure. There is a huge possibility that the trusses will damage or crack when the load is
applied on the bridge. The cable force also has influence the stress of the bridge due to imposed load.
The stress results clearly describes that the stress is much lower than the maximum stress the bridge
can endure. The negative sign means that the bridge main structure is in compression stress.

Figure 15: Deflection result diagram for tank load at Figure 16: Stress result diagram for tank load at first
first position position

Figure 17: Deflection result diagram for tank load at Figure 18: Stress result diagram for tank load at
second position second position
445 Norazman Mohamad Nor, Vivekananthan Devarase
Muhamad Azani Yahya, Suriyadi Sojipto
Siti Khadijah Che Osmi

Figure 19: Deflection result diagram for tank load at Figure 20: Stress result diagram for tank load at third
third position position

Figure 21: Deflection result diagram for tank load at Figure 22: Stress result diagram for tank load at
fourth position fourth position

Figure 23: Deflection result diagram for tank load at Figure 24: Stress result diagram for tank load at fifth
fifth position position

5.2.3. 1000 kN Force Cables Only (No Load Is Applied)

In fact, for this simulation only cable is used to determine how the bridge reacts to the cable forces
without imposing any load. Therefore, this will assist to identify the value of upwards deflection.
Theoretically, this is important because when the bridge is deployed, the cable forces will lift the
bridge upwards to the certain extents and it may affect the mobility of the vehicles that travel across the
bridge. The maximum deflection occurred in the center of the bridge with the value of 601 mm and the
maximum stress of the bridge is 128 MPa. Consequently, with all gathered information, it
demonstrates the deflection upward is considered as normal and will not affect the bridge. The stress
and deflection results are shown in Figure 25 and Figure 26.
Fiber Reinforced Polymer (FRP) Portable Bridge:
Modeling and Simulation 446

Figure 25: Deflection result diagram for 1000 KN Figure 26: Stress result diagram for 1000 KN cable
cable force only force only

5.2.4. Double Tank Load Analysis

In this analysis, the bridge is tested whether it can accommodate double tank load without failing. The
same tensile force is used for the cables. From observation, the bridge still deflects upward although
loads were imposed on it. The maximum deflection of the bridge after subjected to the loads is 389
mm. The maximum stress at the main beam structure is 129 MPa whereas the maximum stress at the
cable truss is 1930 MPa. Both deflection and stresses indicates that (neglecting the cable supporting
trusses) that the bridge can still barely to the two tank loads at the same time. The figures (Figure 27
and Figure 28) below illustrate the results from the analysis.

Figure 27: Deflection result diagram for double tank Figure 28: Stress result diagram for double tank load
load

5.2.5. Result Summary and Recommendation

Based on the results, it can be summarized that the bridge main structure (beam structure) can
accommodate the tank load with tensioning cable in place. The cables with 1000 kN tensile force will
resist the bridge from deflected downward. The bridge alone without the support of the tensioning
cables will deflect excessively. It also indicates that the bridge can accommodate two tanks if required.
In advance, it shows that the tensioning cables play a very significant role resisting excessive
deflection. On the other hand, the cable supporting trusses need to be redesign due to its inability to
resist the deflection and the stress induced by the cable. As a solution, the other potential material
should be used as a replacement for the cable supporting truss.

6. Conclusion
Accordingly, the first objective of this study is to identify the best material to be used for the military
bridges which focusing on composite material. After conducting detail research on FRP material the
best material is selected. The material chosen for the bridge is T300/5208 Carbon/Epoxy. This material
is considered as the other alternative and also been widely used in some countries. Although this
material is not used commonly for accommodating heavy structural load but the material ability to
withstand an enormous load worst venturing into it. Therefore, FRP material can be selected as the best
447 Norazman Mohamad Nor, Vivekananthan Devarase
Muhamad Azani Yahya, Suriyadi Sojipto
Siti Khadijah Che Osmi

material to be used for military bridge is achieved. Otherwise, Solidswork CAD software has been
used to model the bridge based on the CAD software Geometry modeling.
However, the Wireframe modeling also was done by using FEA CAD. The bridge model is
meshed using “tet” element and then was displayed in wireframe model. Thus, the second objective is
achieved. Furthermore, the other objective is to simulate the model, analyzes the effect of the load, and
recommends some improvement. There are 4 categories of simulation is done and three of them is
tensioning cables to stiffening the bridge. The simulation indicates that the cable tensile force applied
is able to stiffen the bridge against excessive deflection. Besides, it also reveals that the cable
supporting truss cannot withstand the stress and deflection caused by the imposed load. Hence, it is
recommended that the size of the members of supporting truss to be enlarged or use an alternative
material for the cable supporting truss. In a nutshell, it explains that the main structure (beam structure)
can accommodate the imposed load safely with the tensioning cables installed under the main
structures. However, the cable supporting truss needs to be strengthening so that the entire bridge
structure can resist the imposed load without any problem.

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