STRENGTHENING

STRUCTURES USING FRP

COMPOSITE MATERIALS
DAMIAN I. KACHLAKEV, Ph.D., P.E.
California Polytechnic State University
San Luis Obispo
 WHY COMPOSITES?
• ADVANTAGES OVER TRADITIONAL
MATERIALS
• CORROSION RESISTANCE
• HIGH STRENGTH TO WEIGHT RATIO
• LOW MAINTENANCE
• EXTENDED SERVICE LIFE
• DESIGN FLEXIBILITY
 COMPOSITES DEFINITION
• A combination of two or more materials (reinforcement,
resin, filler, etc.), differing in form or composition on a
macroscale. The constituents retain their identities, i.e..,
they do not dissolve or merge into each other, although
they act in concert. Normally, the components can be
physically identified and exhibit an interface between
each other.
 DEFINITION
Fiber Reinforced Polymer (FRP) Composites
are defined as:

“A matrix of polymeric material that is

reinforced by fibers or other reinforcing
material”
 COMPOSITES MARKETS
• TRANSPORTATION
• CONSTRUCTION
• MARINE
• CORROSION-RESISTANT
• CONSUMER
• ELECTRICAL/ELECTRONIC
• APPLIANCES/BUSINESS
• AIRCRAFT/DEFENSE
 U.S. COMPOSITES SHIPMENTS - 1996 MARKET SHARE
SEMI-ANNUAL STATISTICAL REPORT - AUGUST 26, 1996

Aircraft/Aerospace
Transportation 0.7%
30.6%
Construction
20%

Other- 3.4%

Consumer
Products - 6%
Marine - 11.6%
Electrical/
Electronic - 10%
Appliance/Business
Corrosion-Resistant Equipment - 5.3%
Equipment - 12.4%

Includes reinforced thermoset and thermoplastic

resin composites, reinforcements and SOURCE: SPI Composites Institute
fillers.
 Infrastructure Benefits
• HIGH STRENGTH/WEIGHT RATIO
• ORIENTATED STRENGTH
• DESIGN FLEXIBILITY
• LIGHTWEIGHT
• CORROSION RESISTANCE
• LOW MAINTENANCE/LONG-TERM DURABILITY
• LARGE PART SIZE POSSIBLE
• TAILORED AESTHETIC APPEARANCE
• DIMENSIONAL STABILITY
• LOW THERMAL CONDUCTIVITY
• LOW INSTALLED COSTS
 FRP COMPOSITE
CONSTITUENTS
• RESINS (POLYMERS)

• REINFORCEMENTS

• FILLERS

• ADDITIVES
 MATERIALS: RESINS
• PRIMARY FUNCTION:
“TO TRANSFER STRESS BETWEEN REINFORCING
FIBERS AND TO PROTECT THEM FROM
MECHANICAL AND ENVIRONMENTAL DAMAGE”

• TYPES:
– THERMOSET
– THERMOPLASTIC
 RESINS
• THERMOSET
– POLYESTER
– VINYL ESTER
– EPOXY
– PHENOLIC
– POLYURETHANE
 RESINS
• THERMOPLASTIC
– ACETAL
– ACRYRONITRILE BUTADIENE STYRENE
(ABS)
– NYLON
– POLYETHYLENE (PE)
– POLYPROPYLENE (PP)
– POLYETHYLENE TEREPHTHALATE (PET)
 RESINS
• THERMOSET ADVANTAGES
– THERMAL STABILITY
– CHEMICAL RESISTANCE
– REDUCED CREEP AND STRESS RELAXATION
– LOW VISCOSITY- EXCELLENT FOR FIBER
ORIENTATION
– COMMON MATERIAL WITH FABRICATORS
 RESINS
• THERMOPLASTIC ADVANTAGES
– ROOM TEMPERATURE MATERIAL STORAGE
– RAPID, LOW COST FORMING
– REFORMABLE
– FORMING PRESSURES AND TEMPERATURES
 POLYESTERS
• LOW COST
• EXTREME PROCESSING VERSATILITY
• LONG HISTORY OF PERFORMANCE
• MAJOR USES:
– Transportation
– Construction
– Marine
 VINYL ESTER
• SIMILAR TO POLYESTER

• EXCELLENT MECHANICAL & FATIGUE

PROPERTIES

• EXCELLENT CHEMICAL RESISTANCE

• MAJOR USES:
– Corrosion Applications - Pipes, Tanks, & Ducts
 EPOXY
• EXCELLENT MECHANICAL PROPERTIES
• GOOD FATIGUE RESISTANCE
• LOW SHRINKAGE
• GOOD HEAT AND CHEMICAL RESISTANCE
• MAJOR USES:
– FRP Strengthening Systems
– FRP Rebars
– FRP Stay-in-Place Forms
 PHENOLICS
• EXCELLENT FIRE RETARDANCE
• LOW SMOKE & TOXICITY EMISSIONS
• HIGH STRENGTH AT HIGH TEMPERATURES
• MAJOR USES:
– Mass Transit - Fire Resistance & High
Temperature
– Ducting
 POLYURETHANE
• TOUGH

• GOOD IMPACT RESISTANCE

• GOOD SURFACE QUALITY

• MAJOR USES:
– Bumper Beams, Automotive Panels
 SUMMARY: POLYMERS
• WIDE VARIETY AVAILABLE
• SELECTION BASED ON:
– PHYSICAL AND MECHANICAL PROPERTIES
OF PRODUCT
– FABRICATION PROCESS REQUIREMENTS
 Physical Properties of Thermosetting
Resins Used in Structural
Composites
Resin Density Tensile Elong. E- Long.
Type (kg/m3) Str. (%) Mod. Term
(MPa) (GPa) t ,(C)
Polyester 1.2 50-65 2-3 3 120

Vinyl 1.15 70-80 4-6 3.5 140

Ester
Epoxy 1.1-1.4 50-90 2-8 3 120-
200
Phenolic 1.2 40-50 1-2 3 120-
150
 MATERIAL: FIBER
REINFORCEMENTS
• PRIMARY FUNCTION:
“CARRY LOAD ALONG THE LENGTH OF THE
FIBER, PROVIDES STRENGTH AND OR STIFFNESS
IN ONE DIRECTION”

• CAN BE ORIENTED TO PROVIDE PROPERTIES IN

DIRECTIONS OF PRIMARY LOADS
 REINFORCEMENTS
• NATURAL

• MAN-MADE

• MANY VARIETIES COMMERCIALLY

AVAILABLE
 MAN-MADE FIBERS
• ARAMID
• BORON
• CARBON/GRAPHITE
• GLASS
• NYLON
• POLYESTER
• POLYETHYLENE
• POLYPROPYLENE
 FIBER PROPERTIES
DENSITY (g/cm3)
Steel 8

Alum 2.76

E-Glass 1.99

S-Glass 1.99

Carbon 1.59

Aramid 1.38

0 2 4 6 8 10
 FIBER PROPERTIES
TENSILE STRENGTH
Alum 20

Steel 60

S-Glass 625

Carbon 530

Aramid 525

E-Glass 500

0 200 400 600 800

x103 psi
 FIBER PROPERTIES
STRAIN TO FAILURE
Alum 0.2

Steel 0.16

S-Glass 5

E-Glass 4.8

Aramid 2.8

Carbon 1.4

0 1 2 3 4 5 6

(%)
 FIBER PROPERTIES
TENSILE MODULUS
Alum 10

Steel 29

Carbon 33.5

Aramid 19

S-Glass 12.6

E-Glass 10.5

0 10 20 30 40

106 psi
 FIBER PROPERTIES
CTE - Longitudinal
14 12.6
12
10
8 6.5
x10 / C
-6 0
6 5
4 2.9
2 0.5
0
-2 Aramid Carbon S-Glass E-Glass Steel Alum
-2
 FIBER PROPERTIES
THERMAL CONDUCTIVITY
1600 1500
1400
1200
1000
x10-6/0C 800
600
400
200 115
1.5 7.5
0
FRP Steel Alum Concrete

BTU-in/hr-ft2 - 0F
 FIBER REINFORCEMENT
• GLASS (E-GLASS)
– MOST COMMON FIBER USED
– HIGH STRENGTH
– GOOD WATER RESISTANCE
– GOOD ELECTRIC INSULATING PROPERTIES
– LOW STIFFNESS
 GLASS TYPES
• E-GLASS
• S-GLASS
• C-GLASS
• ECR-GLASS
• AR-GLASS
 FIBER REINFORCEMENT
• ARAMID (KEVLAR)
– SUPERIOR RESISTANCE TO DAMAGE
(ENERGY ABSORBER)
– GOOD IN TENSION APPLICATIONS (CABLES,
TENDONS)
– MODERATE STIFFNESS
– MORE EXPENSIVE THAN GLASS
 FIBER REINFORCEMENT
• CARBON
– GOOD MODULUS AT HIGH TEMPERATURES
– EXCELLENT STIFFNESS
– MORE EXPENSIVE THAN GLASS
– BRITTLE
– LOW ELECTRIC INSULATING PROPERTIES
 TYPICAL PROPERTIES OF
STRUCTURAL FIBERS
Fiber Density E- Tensile Elong.
Type (kg/m3) Modulus Strength (%)
(GPa) (GPa)
E-Glass 2.54 72.5 1.72-3.45 2.5
S-Glass 2.49 87 2.53-4.48 2.9
Kevlar 29 1.45 85 2.27-3.80 2.8
Kevlar 49 1.45 117 2.27-3.80 1.8
Carbon 1.80 227 2.80-5.10 1.1
(HS)
Carbon 1.80-1.86 370 1.80 0.5
(HM)
Carbon 1.86-2.10 350-520 1.00-1.75 0.2
(UHM)
 ADVANTAGES AND
DISADVANTAGES OF
REINFORCING FIBERS
Fiber Type Advantages Disadvantages

E-Glass, S-Glass High Strength, Low Stiffness,

Low Cost Fatigue
Aramid High Strength, Low Compr.
Low Density Str., High
Moisture
Absorption
HS Carbon High Strength High Cost
and Stiffness
UHM Carbon Very High Low Strength,
Stiffness High Cost
 FIBER ORIENTATION
• ANISOTROPIC
• UNIDIRECTIONAL
• BIAS - TAILORED DIRECTION
– 0O - flexural strengthening
– 90O - column wraps
– + /- 45O - shear strengthening
• ANGLE VARIES BY APPLICATION
DEGREE OF ANISOTROPY OF
FRP COMPOSITES
FRP Composite E1/E2 E1/G12 F1/F2t
Steel 1.00 2.58 1.00
Vinyl Ester 1.00 0.94 1.00
S-Glass/Epoxy 2.44 5.06 28
E-Glass/Epoxy 4.42 8.76 17.7
Carbon/Epoxy 13.64 19.1 41.4
UHM/Epoxy 40 70 90
Kevlar/Epoxy 15.3 27.8 260
 PROPERTIES OF
UNIDIRECTIONAL
COMPOSITES
Property E-Glass/ S-Glass/ Aramid/ Carbon/
Epoxy Epoxy Epoxy Epoxy
Fiber Volume 0.55 0.50 0.60 0.63
Longitudinal Modulus GPa 39 43 87 142
Transverse .Modulus, 8.6 8.9 5.5 10.3
GPa
Shear Modulus, 3.8 4.5 2.2 7.2
GPa
Poisson’s 0.28 0.27 0.34 0.27
Ratio
Long.Tensile Strength 1080 1280 1280 2280
MPa
Compressive Strength, 620 690 335 1440
MPa
ELASTIC AND SHEAR MODULI
OF FRP COMPOSITES
Material E1 E2 G12 G13 G23

Aluminum 10.40 10.40 3.38 3.38 3.38

Steel 29 29 11.24 11.24 11.24

Carbon/Epoxy 20 1.30 1.03 1.03 0.90

Glass/Epoxy 7.80 2.60 1.25 1.25 0.50

 REINFORCEMENTS
SUMMARY
• TAILORING MECHANICAL PROPERTIES
– TYPE OF FIBER
– PERCENTAGE OF FIBER
– ORIENTATION OF FIBER
 COMPARISON OF AXIAL AND
FLEXURAL EFFICIENCY OF FRP
SYSTEMS
AXIAL FLEXURAL
EFFICIENCY EFFICIENCY
Material E/ Rank E1/2/ Rank

Carbon/Epoxy 113.1 1 8.4 1

Kevlar/Epoxy 52.1 2 6.0 2

E-Glass/Epoxy 21.4 4 3.5 3

Mild Steel 25.6 3 1.8 4

 DESIGN VARIABLES
FOR COMPOSITES
• TYPE OF FIBER
• PERCENTAGE OF FIBER or FIBER VOLUME
• ORIENTATION OF FIBER
– 0o, 90o, +45o, -45o
• TYPE OF POLYMER (RESIN)
• COST
• VOLUME OF PRODUCT - MANUFACTURING
METHOD
 DESIGN VARIABLES
FOR COMPOSITES
• PHYSICAL:
– tensile strength
– compression strength
– stiffness
– weight, etc.
• ENVIRONMENTAL:
– Fire
– UV
– Corrosion Resistance
 TAILORING COMPOSITE
PROPERTIES
• MAJOR FEATURE
• PLACE MATERIALS WHERE NEEDED - ORIENTED
STRENGTH
– LONGITUDINAL
– TRANSVERSE
– or between
• STRENGTH
• STIFFNESS
• FIRE RETARDANCY
 STRUCTURAL DESIGN
APPROACH FOR COMPOSITES

S tru c tu ral D es ig n W ith F R P C om p os ites

S TR U C TU R E
F R P R ep air

M atrix, F ib ers L am in a, L am in ate S tru c tu ral A n alys is

M ic rom ec h an ic s M ac rom ec h an ic s S tren g th e n in g D e s ig n
SPECIFIC MODULUS AND STRENGTH
OF FRP COMPOSITE
FLOW CHART FOR DESIGN OF
FRP COMPOSITES
[E ]1 ,2
E n g in eerin g C o n s tan ts

[Q ]1 ,2 [F ib er O rien tation ] [S ] 1 ,2
M ath em atic al C on s tan ts M ath em atic al C on s tan ts

[Q ] x,y [S ] x,y
Tran s form ed M ath . C on s tan ts Tran s form ed M ath . C on s tan ts

[E ] x,y [E ] x,y
Tran s form ed E n g . C on stan ts Tran s form ed E n g . C on s tan ts
 MANUFACTURING
PROCESSES
• Hand Lay-up/Spray-up
• Resin Transfer Molding (RTM)
• Compression Molding
• Injection Molding
• Reinforced Reaction Injection Molding (RRIM)
• Pultrusion
• Filament Winding
• Vacuum Assisted RTM (Va-RTM)
• Centrifugal Casting
PROCESS CHARACTERISTICS
Hand Lay-up/Spray-up
• MAX SIZE: Unlimited
• PART GEOMETRY: Simple - Complex
• PRODUCTION VOLUME: Low - Med
• CYCLE TIME: Slow
• SURFACE FINISH: Good - Excellent
• TOOLING COST: Low
• EQUIPMENT COST: Low
PRODUCT CHARACTERISTICS
Pultrusion

• CONSTANT CROSS SECTION

• CONTINUOUS LENGTH
• HIGH ORIENTED STRENGTHS
• COMPLEX PROFILES POSSIBLE
• HYBRID REINFORCEMENTS
 MATERIAL PROPERTIES
• PROPERTIES OF FRP COMPOSITES VARY
DEPENDING ON:
– TYPE OF FIBER & RESIN SELECTED
– FIBER CONTENT
– FIBER ORIENTATION
– MANUFACTURING PROCESS
 REPAIR
• HYBRIDS (SUPER COMPOSITES): TRADITIONAL
MATERIALS ARE JOINED WITH FRP
COMPOSITES
– WOOD
– STEEL
– CONCRETE
– ALUMINUM
 BENEFITS - SUMMARY
• LIGHT WEIGHT
• HIGH STRENGTH to WEIGHT RATIO
• COMPLEX PART GEOMETRY
• COMPOUND SURFACE SHAPE
• PARTS CONSOLIDATION
• DESIGN FLEXIBILITY
• LOW SPECIFIC GRAVITY
• LOW THERMAL CONDUCTIVITY
• HIGH DIELECTRIC STRENGTH
 LIFE CYCLE ECONOMICS
• PLANNING/DESIGN/DEVELOPMENT COST
• PURCHASE COST
• INSTALLATION COST
• MAINTENANCE COST
• LOSS/WEAR COST
• LIABILITY/INSURANCE COSTS
• DOWNTIME/LOST BUSINESS COST
• REPLACEMENT/DISPOSAL/RECYCLING
COST
 LIFE CYCLE ECONOMICS
(Examples)
• IBACH BRIDGE (SWITZERLAND)
– CFRP LAMINATES- 50 TIMES MORE
EXPENSIVE THAN STEEL PER KILOGRAM
– CFRP LAMINATES- 9 TIMES MORE
EXPENSIVE THAN STEEL BY VOLUME
– REPAIR WORK REQUIREMENTS-175 KG
STEEL OR 6.2 KG CFRP
– MATERIAL COST-20 % OF THE TOTAL
PROJECT COST
 LIFE CYCLE ECONOMICS
(Examples)
• HORSETAIL CREEK BRIDGE (OREGON)
– CONVENTIONAL REPAIR (SHEAR ONLY-ONE
BEAM)-$69,000
– FRP REPAIR (GFRP SHEAR ONLY-ONE BEAM)-
$1850
– FRP REPAIR [SHEAR (GFRP)+
FLEXURE(CFRP), ONE BEAM]- $9850
 CONCLUSIONS
• ECONOMICS ARE MORE THAN THE BASIC
ELEMENTS OF MATERIALS, LABOR,
EQUIPMENT, OVERHEAD, ETC.
• ENTIRE LIFE CYCLE ECONOMICS MUST BE
CONSIDERED AND COMPARED TO THAT OF
TRADITIONAL MATERIALS TO DETERMINE THE
BENEFITS OF COMPOSITES IN A GIVEN
APPLICATION
STRUCTURAL DESIGN WITH
FRP COMPOSITES
EXTERNAL REINFORCEMENT OF
RC BEAMS USING FRP
• BACKGROUND
• DESIGN MODELS
– LACK OF DUCTILITY
– FLEXURAL STRENGTHENING
– SHEAR STRENGTHENING
– PRESTRESSED FRP APPLICATION
• DESIGN METHODOLOGY AND ANALYSIS
• OTHER ISSUES
– FATIGUE, CREEP, LOW TEMPERATURE FRP
PERFORMANCE
• DESIGN EXAMPLES
FRP STRENGTHENED BEAMS
BACKGROUND
• FRP VS. EXTERNALLY STEEL BONDED
PLATES
– CORROSION AT THE EPOXY-STEEL INTERFACE
– STEEL PLATES DO NOT INCREASE STRENGTH,
JUST STIFFNESS
– HIGH TEMPERATURES PERFORMANCE
DIFFICULTIES DUE TO HEAVY WEIGHT OF THE
STEEL PLATES
– STRENGTHENING DESIGN BASED ON MATERIAL
WEIGHT, NOT STRUCTURAL NEEDS
– CONSTRUCTION DIFFICULTIES
– TIME CONSUMING, HEAVY EQUIPMENT NEEDED
FRP STRENGTHENED BEAMS
LACK OF DUCTILITY

• LINEAR STRESS-STRAIN PROFILE

• DEFINITION OF DUCTILITY
– DEFLECTION AT ULTIMATE/DEFLECTION AT
YIELD- NOT APPLICABLE FOR FRP MATERIAL
– STRAIN-ENERGY ABSORPTION, I.E., AREA UNDER
LOAD-DEFLECTION CURVE- OK FOR FRP
COMPOSITES
– IN GENERAL- THE HIGHER THE FRP FRACTION
AREA, THE LOWER THE ENERGY ABSORPTION OF
THE STRENGTHENED CONCRETE BEAM
FRP STRENGTHENED BEAMS
TYPICAL LOAD-DEFLECTION
CURVE
FRP REINFORCED BEAMS-
FAILURE MODES
FRP REINFORCEMENT OF RC
COLUMNS
• Advantages of Strengthening Columns with
FRP Jackets
– Increased Ductility
– Increased Strength
– Low Dead Weight
– Reduced Construction Time
– Low Maintenance
FRP REINFORCEMENT OF RC
COLUMNS
• Factors Influencing the Behavior of FRP-
Retrofitted Columns
– Column composition
– Column geometry
– Current condition
– Type of loading
– Environmental conditions
DESIGN OF FRP RETROFIT OF
RC COLUMNS
• Shear Strengthening
• Flexural Hinge Confinement
• Lap Splice Clamping
LOAD-DISPLACEMENT CURVE
(Before Strengthening)
LOAD-DISPLACEMENT CURVE
(After Strengthening)
COLUMN DUCTILITY
FRP REINFORCEMENT OF RC
COLUMNS
• Advantages of Strengthening Columns with
FRP Jackets
– Increased Ductility
– Increased Strength
– Low Dead Weight
– Reduced Construction Time
– Low Maintenance
FRP REINFORCEMENT OF RC
COLUMNS
• Factors Influencing the Behavior of FRP-
Retrofitted Columns
– Column composition
– Column geometry
– Current condition
– Type of loading
– Environmental conditions
LOAD-DISPLACEMENT
CURVE
(Before Strengthening)
LOAD-DISPLACEMENT CURVE
(After Strengthening)
COLUMN DUCTILITY
 CONSTRUCTION PROCESS
• Preparation of the Concrete Surface
• Mixing Epoxy, Putty, etc.
• Preparation of the FRP Composite System
• Application of the FRP Strengthening System
• Anchorage (if recommended)
• Curing the FRP Material
• Application of Finish System
 CONCRETE SURFACE
PREPARATION
• Repair of the existing concrete in accordance to:
– ACI 546R-96 “Concrete Repair Guide”
– ICRI Guideline No. 03370 “Guide for Surface
Preparation for the Repair of Deteriorated
Concrete...”
• Bond Between Concrete and FRP Materials
– Should satisfy ICRI “Guide for Selecting and
Specifying Materials for Repair of Concrete
Surfaces”
 CONCRETE SURFACE
PREPARATION
• Repair Cracks 0.010 inches or Wider
– Epoxy pressure injected
– To satisfy Section 3.2 of the ACI 224.1R-93
“Causes, Evaluation and Repair of Cracks…”
• Concrete Surface Unevenness to be Less than 1
mm
• Concrete Corners- Minimum Radius of 30 mm
 APPLICATION OF THE FRP
COMPOSITE
• In Accordance to Manufacturer’s and Designer's
Specifications
– Priming
– Putty Application
– Under-coating with Epoxy Resin
– Application of the FRP Laminate/ FRP Fiber Sheet
– Over-coating with Epoxy Resin
 CURING OF THE FRP
COMPOSITES
• In Accordance to Manufacturer’s Specifications
– Temperature ranges and Curing Time- varies from
few hours to 15 days for different FRP systems
• Cured FRP Composite
– Uniform thickness and density
– Lack of porosity
CONSTRUCTION PROCESS
• Typical RC Beam in
Need for Repair
– corroded steel
– spalling concrete
CONSTRUCTION PROCESS
• Deteriorated Column /
Beam Connection
CONSTRUCTION PROCESS
• Concrete Surface
Preparation
– Smooth, free of dust and
foreign objects, oil, etc.
– Application of primer
and putty (if required by
the manufacturer)
CONSTRUCTION PROCESS
• Preparation of the FRP
Composites for
Application
– Follow
manufacturer’s
recommendations
CONSTRUCTION PROCESS
• Priming of the Concrete
Surface
• Application of the
Undercoating epoxy
Layer (adhesive when
FRP pultruded laminates
are used)
CONSTRUCTION PROCESS
• Application of CFRP
Fiber Sheet on a Beam-
Wet Lay-Up Process
• Similar for Application
of Pultruded Laminates
CONSTRUCTION PROCESS
• Column Wrapping with
Automated FRP
Application device
CONSTRUCTION PROCESS
• Robo Wrapper by Xxsys
Technologies
CONSTRUCTION PROCESS
• Column Wrapping
Device