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ISIS Educational Module 2:

An Introduction to FRP
Composites for Construction

Prepared by ISIS Canada


A Canadian Network of Centres of Excellence
www.isiscanada.com
Principal Contributor: L.A. Bisby, Ph.D., P.Eng.
Department of Civil Engineering, Queen’s University
Contributor: J. Fitzwilliam
March 2006

ISIS Education Committee:

N. Banthia, University of British Columbia


L. Bisby, Queen’s University
R. Cheng, University of Alberta
R. El-Hacha, University of Calgary
G. Fallis, Vector Construction Group
R. Hutchinson, Red River College
A. Mufti, University of Manitoba
K.W. Neale, Université de Sherbrooke
J. Newhook, Dalhousie University
K. Soudki, University of Waterloo
L. Wegner, University of Saskatchewan
ISIS Canada Educational Module No. 2: FRP Composites for Construction

Objectives of This Module


The objective of this module is to provide students with an methodologies of the past, and FRPs are rapidly emerging
overall awareness of the properties, behaviour, and as key materials for use in durable and sustainable
application of fibre reinforced polymer (FRP) materials in infrastructure.
civil engineering construction applications. This document The primary objectives of this manual can be
is one of a series of modules on innovative FRP summarized as follows:
technologies available from ISIS Canada. Further 1. to provide civil engineering students with a general
information on FRP materials and on the use of FRPs in a awareness of the properties and behaviour of FRP
variety of innovative applications can be found on the materials;
internet at www.isiscanada.com. While research into the use 2. to provide information on some of the potential uses of
of FRP materials in a number of structural applications is FRPs in civil engineering applications;
ongoing, an overall knowledge of currently available FRP 3. to facilitate the use of FRP materials in the construction
materials is essential for the new generation of civil industry; and
engineers. Experience has shown that the problems of the 4. to provide guidance for students seeking additional
future cannot generally be solved with the materials and information on this topic.

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Additional ISIS Educational Modules


Available from ISIS Canada (www.isiscanada.com)

Module 1 – Mechanics Examples Incorporating FRP Module 6 – Application & Handling of FRP
Materials Reinforcements for Concrete

Nineteen worked mechanics of materials problems are presented Important considerations in the handling and application of FRP
which incorporate FRP materials. These examples could be used materials for both reinforcement and strengthening of reinforced
in lectures to demonstrate various mechanics concepts, or could be concrete structures are presented in detail. Introductory
assigned for assignment or exam problems. This module seeks to information on FRP materials, their mechanical properties, and
expose first and second year undergraduates to FRP materials at their applications in civil engineering applications is provided.
the introductory level. Mechanics topics covered at the Handling and application of FRP materials as internal
elementary level include: equilibrium, stress, strain and reinforcement for concrete structures is treated in detail, including
deformation, elasticity, plasticity, determinacy, thermal stress and discussions on: grades, sizes, and bar identification, handling and
strain, flexure and shear in beams, torsion, composite beams, and storage, placement and assembly, quality control (QC) and quality
deflections. assurance (QA), and safety precautions. This is followed by
information on handling and application of FRP repair materials
Module 3 – Introduction to FRP-Reinforced for concrete structures, including: handling and storage,
installation, QC, QA, safety, and maintenance and repair of FRP
Concrete
systems.
The use of FRP bars, rods, and tendons as internal tensile
reinforcement for new concrete structures is presented and Module 7 – Introduction to Life Cycle Engineering &
discussed in detail. Included are discussions of FRP materials Costing for Innovative Infrastructure
relevant to these applications, flexural design guidelines,
serviceability criteria, deformability, bar spacing, and various Life cycle costing (LCC) is a well-recognized means of guiding
additional considerations. A number of case studies are also design, rehabilitation and on-going management decisions
discussed. A series of worked example problems, a suggested involving infrastructure systems. LCC can be employed to enable
assignment with solutions, and a suggested laboratory and encourage the use of fibre reinforced polymers (FRPs) and
incorporating FRP-reinforced concrete beams are all included. fibre optic sensor (FOS) technologies across a broad range of
infrastructure applications and circumstances, even where the
Module 4 – Introduction to FRP-Strengthening of initial costs of innovations exceed those of conventional
alternatives. The objective of this module is to provide
Concrete Structures undergraduate engineering students with a general awareness of
the principles of LCC, particularly as it applies to the use of fibre
The use of externally-bonded FRP reinforcement for strengthening reinforced polymers (FRPs) and structural health monitoring
concrete structures is discussed in detail. FRP materials relevant (SHM) in civil engineering applications.
to these applications are first presented, followed by detailed
discussions of FRP-strengthening of concrete structures in flexure,
shear, and axial compression. A series of worked examples are Module 8 – Durability of FRP Composites for
presented, case studies are outlined, and additional, more Construction
specialized, applications are introduced. A suggested assignment
is provided with worked solutions, and a potential laboratory for Fibre reinforced polymers (FRPs), like all engineering materials,
strengthening concrete beams in flexure with externally-bonded are potentially susceptible to a variety of environmental factors
FRP sheets is outlined. that may influence their long-term durability. It is thus important,
when contemplating the use of FRP materials in a specific
Module 5 – Introduction to Structural Health application, that allowance be made for potentially harmful
environments and conditions. It is shown in this module that
Monitoring
modern FRP materials are extremely durable and that they have
tremendous promise in infrastructure applications. The objective of
The overall motivation behind, and the benefits, design,
this module is to provide engineering students with an overall
application, and use of, structural health monitoring (SHM)
awareness and understanding of the various environmental factors
systems for infrastructure are presented and discussed at the
that are currently considered significant with respect to the
introductory level. The motivation and goals of SHM are first
durability of fibre reinforced polymer (FRP) materials in civil
presented and discussed, followed by descriptions of the various
engineering applications.
components, categories, and classifications of SHM systems.
Typical SHM methodologies are outlined, innovative fibre optic
sensor technology is briefly covered, and types of tests which can
be carried out using SHM are explained. Finally, a series of SHM
case studies is provided to demonstrate four field applications of
SHM systems in Canada.

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Section 1
Introduction and Overview
BACKGROUND steel. Some of the commonly cited advantages of FRP
The construction industry has historically been dominated materials over more conventional materials like steel
by four traditional materials: stone, timber, concrete, and include:
steel. Up until a few hundred years ago, stone and timber • high strength-to-weight ratios;
were the primary materials used to build structures. In the • outstanding durability in a variety of environments;
past two hundred years or so, structural steel and reinforced • ease and speed of installation, flexibility, and
concrete have emerged as leading construction materials, application techniques;
and most modern urban landscapes are now defined largely • electromagnetic neutrality, which can be important in
by these two materials. Steel and concrete have served the certain special structures such as magnetic imaging
civil engineering community well, and have enabled the facilities;
construction of the elaborate world-wide systems of • the ability to tailor mechanical properties by
infrastructure that have greatly contributed to the economic appropriate choice and direction of fibres;
health and prosperity of the developed world. However, • outstanding fatigue characteristics (carbon FRP); and
steel and concrete both suffer from various forms of low thermal conductivity.
degradation, and after decades of neglect and overuse, our
aging infrastructure systems are crumbling (Fig. 1-1).
In an effort to slow and/or prevent infrastructure
deterioration, engineers are looking for new materials that
can be used to prolong and extend the service lives of
existing structures while also enabling the design and
construction of durable new structures. Fibre reinforced
polymers (FRPs), a relatively new class of non-corrosive,
high-strength, and lightweight materials, have, over the past
15 years or so, emerged as practical materials for a number
of structural engineering applications.
FRPs have been used in the automotive and aerospace
industries for more than 50 years, in applications where
their high strength and light weight can be used to greatest
advantage. As their name suggests, these materials are
composed of high-strength fibres embedded in a polymer
matrix. The fibres are extremely strong and stiff, and the
matrix binds them and enables them to work together as a
composite material.
The focus in the present discussion is on those FRP
materials that are currently used in structural engineering
applications. It is important to remain cognizant of the fact
that many different material combinations (combinations of
fibre and matrix) are possible, and that only a very small Fig. 1-1. Severely corroded reinforcing steel in
sample of the almost infinite number of possibilities is these bridge columns has resulted in spalling of
presented herein. The reader should also keep in mind that the concrete cover and exposure of the steel
several different manufacturing techniques, component reinforcement. New repair techniques for these
shapes, and end-use applications are also available for FRP types of members are now available which make
materials, but that only those most relevant to structural use of FRP materials.
engineering are discussed in this document. More complete
discussions of FRP materials are available in various However, FRP materials also have a number of
composite materials texts. potential disadvantages. Foremost among these
The rapid increase in the use of FRP materials for disadvantages is the initial material cost of FRPs, which can
structural engineering applications that has occurred over be several times that of steel. However, when the cost of a
the past 15 years can be attributed to continuing reductions structure is considered over its entire life cycle, the
in cost, and to the numerous advantages of FRPs as improved durability offered by FRP materials can make
compared with conventional materials such as concrete and them the most cost-effective material in many cases.

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Fig. 1-2. An example of a flexible carbon FRP sheet Fig. 1-3. Examples of currently available glass fibre
that can be used for repair of concrete structures. FRP reinforcing bars for concrete.

FRPS IN CONSTRUCTION
Since the early 1990’s, interest in the use of FRP materials
for structures has increased steadily, and there are currently
hundreds of field applications of FRPs in structures around
the world. Some of the more common FRP applications in
civil engineering structures are described in detail in
Section 5 of this document, and include:
• Externally-bonded FRP plates, sheets, and wraps for
strengthening of reinforced concrete, steel, aluminum,
and timber structural members (Fig. 1-2);
• FRP bars, rods, and tendons for internal reinforcement
of concrete (Figs. 1-3 and 1-4);
• all-FRP structures; and
• FRP hybrid structures.
This module presents an introduction into the properties Fig. 1-4. Examples of currently available carbon
and uses of FRP materials in civil engineering structures, FRP reinforcing bars for concrete.
with a particular emphasis on their use for reinforcement
and strengthening of structural concrete.

Section 2
Fibre Reinforced Polymer (FRP)
GENERAL

FRPs are a subgroup of the class of materials referred to composites have been in use in civil engineering for
more generally as composites. Composites are defined as hundreds of years (e.g. concrete, a composite material
materials created by the combination of two or more composed primarily of gravel, sand, and cement paste).
materials, on a macroscopic scale, to form a new and useful Indeed, organic composite materials also exist throughout
material with enhanced properties that are superior to those nature. Wood and bone are both examples of natural
of the individual constituents alone. composite materials of tremendous strength. Bone, for
When most people think of composite materials, they example, is composed of fibres of the protein collagen,
tend to consider one of a number of advanced material bound together by a crystalline calcium compound called
systems developed in the modern era. However, many apatite.

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

between the fibres and the matrix is thus a key factor in


obtaining good mechanical properties.
A polymer matrix is an organic compound comprised of
long-chain molecules consisting of smaller repeated units
called monomers. Although an enormous variety of polymer
+ = matrix materials exist for the manufacture of FRP materials,
the focus herein is on FRPs used in infrastructure
applications, and thus only a few specific matrix materials
are discussed.
Matrix materials for FRPs can be grouped into two
broad categories: thermoplastics and thermosetting resins.
FIBRES POLYMER FRP
MATRIX Thermoplastics include such polymer compounds as
polyethylene, nylon, and polyamides, while thermosetting
Fig. 2-1. Basic material components that are materials include epoxies and vinylesters.
combined to create an FRP composite. Thermoplastics are polymers composed of long-chain
molecules that are held together by relatively weak Van der
An FRP is a specific type of two-component composite Waals forces, but that have extremely strong bonds within
material consisting of high strength fibres embedded in a individual molecules. In these materials, the molecules are
polymer matrix. The study of FRPs is complicated by the free to slide over one another at elevated temperatures, and
innumerable combinations of materials that can be used to so thermoplastics can be repeatedly softened and hardened
create an FRP composite. This is both an advantage and a by heating and cooling without significantly changing their
disadvantage for FRPs as engineering materials. For molecular structure. Thermosetting polymers are also
instance, FRPs can be tailored to suit virtually any composed of long-chain molecules built from monomers,
application; however, this versatility leads to a wide range but for these materials the molecular chains are cross-linked
in possible properties, making it difficult in many cases to through primary chemical bonds. Thus, thermosets cannot
arrive at generalizations with respect to FRP behaviour. be reversibly softened and will deteriorate irreversibly at
Because FRPs are composed of two distinct materials, elevated temperatures.
overall FRP material properties depend primarily on those Almost exclusively, thermosets are currently used in
of the individual constituents. It is thus instructive to structural engineering applications. These polymers
examine the role and properties of each of the component generally have good thermal stability at service
materials, the fibres and the matrix, separately, before temperatures, good chemical resistance, and display low
discussing the properties of the FRP composite as a whole. creep and relaxation properties in comparison with most
thermoplastics. However, because it is difficult to reversibly
MATRIX soften thermosets, FRP components made from thermoset
matrices must be bent or formed during the manufacturing
The matrix is the binder of the FRP and plays many process. This can become a problem in some specific
important roles. Some of the more critical functions played applications. For instance, FRP reinforcing bars for
by the matrix are: concrete that incorporate thermosetting polymer resins
• to bind the fibres together; cannot be bent on site, and research is currently underway to
• to protect the fibres from abrasion and environmental develop satisfactory thermoplastic matrices for these
degradation; specialized applications.
• to separate and disperse fibres within the composite; Three specific types of thermosetting resins are
• to transfer force between the individual fibres; and commonly used in the manufacture of infrastructure
composites: polyesters, vinylesters, and epoxies.
• to be chemically and thermally compatible with the
fibres.
A major selection criterion for matrix materials is that Polyesters
they have a low density, usually considerably less than the Polyesters are the most widely used polymers in the
fibres, such that the overall weight of the composite is manufacture of FRP components for infrastructure
minimized. applications due to their relatively low cost and ease of
While the fibres provide the strength and stiffness of an processing (these resins cure at ambient temperatures).
FRP, the matrix is essential to transfer forces between the Numerous specific types of polyesters are available for use,
individual fibres. This force transfer is accomplished with varying degrees of thermal and chemical stability,
through shear stresses that develop in the matrix between moisture absorption, and shrinkage during curing.
the individual fibres. Obviously, the quality of the bond

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Vinylesters civil engineering applications, the three most commonly


Vinylesters are often identified as a class of polyesters used fibre types are glass, carbon (graphite), and to a lesser
because of their similar processing procedures. However, in extent, aramid (KevlarTM). The suitability of the various
chemical structure they are essentially unsaturated epoxides, fibres for specific applications depends on a number of
and so their properties are more akin to epoxies. Vinylesters factors including the required strength, the stiffness,
are resistant to strong acids and alkalis, which is one reason durability considerations, cost constraints, and the
that they are commonly used in the manufacture of FRP availability of component materials. Figure 2-3 shows
reinforcing bars for concrete (the environment inside typical stress-strain curves for various currently available
concrete is highly alkaline). Vinylesters also offer reduced fibres. Note that these curves are for the pure fibres only,
moisture absorption and shrinkage as compared with and they do not include the effects of the polymer matrix.
polyesters. Vinylesters cost slightly more than polyesters.

Epoxies
Epoxies are often used in wet lay-up applications of FRP
plates and sheets (discussed in detail later) because of their
ability to cure well at room temperature and owing to their
outstanding adhesion (bonding) characteristics. Epoxies
have high strength, good dimensional stability, relatively
good high-temperature properties, strong resistance to
chemicals (except acids), and superior toughness. Epoxies,
however, cost significantly more than polyesters or
vinylesters.

FIBRES
Fig. 2-2. Scanning electron micrograph showing
The fibres provide the strength and stiffness of an FRP. microscopic carbon fibres used in FRP fabrication.
Because the fibres used in most structural FRP applications
are continuous and are oriented in specified directions, FRPs Glass Fibres
are orthotropic, and they are much stronger and stiffer in the Glass fibres are commonly produced by a process called
fibre direction(s). Fibres are generally selected to have: direct melt, wherein fibres with a diameter of 3 to 25
• high stiffness; microns are formed by rapid and continuous drawing from a
• high ultimate strength; glass melt. Glass fibres are the most inexpensive, and
• low variation of strength between individual fibres; consequently the most commonly used, fibres in structural
• stability during handling; and engineering applications. There are several different grades
• uniform diameter. available, but the most common are E-glass and the more
For structural engineering applications, fibres are also expensive, but stronger, R-glass. Glass fibres are
characterized by extremely large length-to-diameter ratios characterized by their high strength, moderate modulus of
(they are considered continuous) and by extremely small elasticity and density, and by their low thermal conductivity.
diameters (as small as 5-10 microns across, refer to Glass fibres are often chosen for structural applications that
Figure 2-2). The small diameter of the fibres is significant, are not weight critical (glass FRPs are heavier than carbon
in that the molecular structure of the material is aligned or aramid) and that can tolerate the larger deflections
along the length of the fibres giving them high tensile resulting from the comparatively low elastic modulus of the
strength. Also since the probability of a sample of material glass fibres. Glass fibres are often used in the manufacture
containing a flaw large enough to cause brittle failure of FRP reinforcing bars, pultruded FRP structural sections,
decreases with its volume, microscopic fibres have fewer FRP wraps for seismic upgrade, and filament wound FRP
defects than the bulk fibre material, and hence higher tubes.
strengths. In the event of a single fibre break within the
FRP, force transfer to adjacent fibres, through shear stresses Carbon Fibres
that develop in the polymer matrix, prevents failure of the Carbon fibres are produced by a process called controlled
overall FRP composite. It is important to note that the force pyrolysis, wherein one of three potential precursor fibres is
transfer required to prevent overall failure of the FRP subjected to a complex series of heat treatments
depends primarily on the shear strength of the matrix. (stabilization, carbonization, graphitization, and surface
Many different types of fibres are available for use, and treatment) to produce carbon filaments with diameters in the
50 μm In
all have their respective advantages and disadvantages. rage of 5-8 microns. The resulting fibres can have
properties that vary widely, and so several classes of carbon

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

fibres are available, differentiated based on their elastic FRPs their unique physical and mechanical characteristics.
moduli: The orientation of the fibres within the matrix is a key
• standard, 250-300 GPa consideration in the design and use of FRP materials. In the
• intermediate, 300-350 GPa present discussion we will focus on unidirectional FRPs, or
• high, 350-550 GPa on FRPs in which the fibres are all aligned in a single
• ultra-high, 550-1000 GPa direction. Unidirectional FRPs are commonly used for FRP
Although considerably more expensive than glass reinforcing rods and tendons, FRP wraps for concrete
fibres, carbon fibres are beginning to see widespread use in rehabilitation, and pultruded FRP structural sections (all
structural engineering applications such as prestressing discussed in detail later in this document).
tendons for concrete and structural FRP wraps for repair and Figure 2-4 shows various FRP products currently used
strengthening of reinforced concrete beams, columns, and for reinforcement or rehabilitation of concrete structures,
slabs. Their steadily increasing use can be attributed to their and Figure 2-5 shows a number of pultruded FRP structural
steadily decreasing cost, their high elastic moduli and sections.
available strengths, their low density (low weight), and their
outstanding resistance to thermal, chemical, and
environmental effects. Carbon fibres are an ideal choice for
structures which are weight and/or deflection sensitive.

6000
E-Glass
Aramid-49
5000 Standard Carbon
High-Modulus Carbon
Ultra High-Modulus
Stress (MPa)

4000 Reinforcing Steel

3000

2000

1000

0
0 1 2 3 4 5
Strain (%)

Fig. 2-3. Stress-strain properties of typical fibres.


Fig. 2-4. Assorted FRP products currently used for
reinforcement or rehabilitation of concrete
Aramid Fibres
structures.
Aramid fibres are manufactured from a synthetic compound
called aromatic polyamide in a process called extrusion and In North America, glass and carbon are the two most
spinning. Two stiffness grades are readily available: 60 commonly used fibres, and matrices are generally epoxies or
GPa and 120 GPa. Aramid fibres are characterized by high vinylesters. Aramid fibres and polyester resins are also used
strength, moderate elastic modulus, and low density. In very occasionally. Glass is widely used because of its
addition, FRPs manufactured from aramid fibres have low comparatively low cost, and because there is historically
compressive and shear strengths as a consequence of the much more experience with it. However, glass fibres have
unique anisotropic properties of the fibres. Aramid fibres demonstrated certain significant disadvantages, such as a
are also susceptible to degradation from exposure to relatively low elastic modulus and some durability concerns
ultraviolet radiation and/or moisture. in alkaline environments. These disadvantages have made
carbon FRPs, with elastic moduli that can compare more
FRPs closely with steel, more attractive, even given their
considerably higher cost. The primary concerns associated
Although the strength and stiffness of an FRP are governed with aramid FRPs are that they are sensitive to creep and
by the fibres, the overall material properties depend also on have displayed poor durability characteristics resulting from
the mechanical properties of the matrix, the fibre volume their propensity for moisture absorption. Aramid fibres also
fraction (the volume of fibres per unit volume of FRP), the perform poorly at high temperature. Table 3-3 provides a
fibre cross-sectional area, the orientation of the fibres within comparison of various types of FRPs based on a number of
the matrix, and the method of manufacturing. It is the important criteria.
interaction between the fibres and the matrix that gives

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

MANUFACTURING TECHNIQUES raw fibres) into the resin. In some cases, additional resin is
added to the outer surface of the fibres to ensure that they
are fully impregnated. Additional layers of FRP can be
As stated earlier, there is a wide variety of techniques by
added on top of each other to achieve any desired thickness
which FRP components can be manufactured. However,
of FRP. In structural rehabilitation applications, the mould
only those manufacturing methods of immediate interest to
is simply the existing structural member to be strengthened,
the structural engineer are included herein. Pultrusion, wet
and the FRP remains bonded to the mould after curing
lay-up, and filament winding are all discussed in some
(which is normally accomplished at ambient temperature).
detail, while other techniques such as pull-winding, resin
This technique has the advantage that it is easily and rapidly
transfer molding, vacuum bag molding, and injection
performed in the field, providing significant financial
molding are left to specialized composite materials texts.
advantages over conventional structural rehabilitation
techniques such as external plating with steel. However,
Pultrusion quality control is extremely important in this procedure, and
A manufacturing process called pultrusion is commonly skilled labour is often required. Wet lay-up for structural
used to produce FRP bars, rods, tendons, plates, and rehabilitation of a concrete column is illustrated in
structural sections. The technique is fully automated and is Figure 2-8.
thus highly economical. It is similar to the extrusion process
by which many metal sections are fabricated. Illustrated in
Figures 2-6 and 2-7, the pultrusion process is accomplished
by pulling raw fibres through a resin bath and then through a shaping and
heated die. As the resin-impregnated fibres pass through the heating die puller
die the polymer matrix hardens into the shape of the die,
thus producing a structural component. The FRP
component is pulled from the cured end. This process is
continuous and has the advantage that FRP components of creel
resin tank
virtually any length can be fabricated. The reader will note
that all of the fibres in a pultruded element are aligned along Fig. 2-6. Schematic showing the pultrusion
the length of the component, thus creating a unidirectional manufacturing process.
FRP.

Fig. 2-7. Glass fibres being drawn off of creels and


used in the fabrication of pultruded glass FRP
reinforcing bars for concrete.
Fig. 2-5. Various available pultruded FRP structural
sections.
Filament Winding
Many innovative applications of FRPs in structural
engineering, such as stay-in-place formwork for concrete
Wet Lay-Up (Hand Lay-Up) piles (discussed later) make use of hollow FRP poles, pipes,
Wet lay-up, sometimes referred to as hand lay-up or contact and tubes. These members are commonly produced using a
molding, is an FRP manufacturing technique often used in manufacturing process called filament winding. In this
structural rehabilitation applications, where FRP sheets or automated process, illustrated in Figures 2-9 and 2-10, raw
fabrics are bonded to the exterior of reinforced concrete, fibres are drawn off spools, through a resin bath, and wound
steel, aluminum, or timber members. In this technique, a onto a rotating mandrel. The placement of the fibres on the
rigid mould is covered with resin and a roller is used to mandrel is controlled by a computer, allowing for the fibres
press the fibres (usually in the form of a sheet or fabric of to be placed with extreme precision and with various desired

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

orientations. By varying the fibre orientation, filament Fibre Roving


wound members can be created with a variety of mechanical
properties tailored for specific applications.
Mobile Resin Bath

Rotating Mandrel Motor

Fig. 2-9. A schematic showing the filament winding


manufacturing process.

Fig. 2-8. Glass FRP sheets being applied to


strengthen a reinforced concrete column using the
wet lay-up (hand lay-up) procedure. Fig. 2-10. Glass fibres being wound onto a
triangular mandrel during the fabrication of
triangular filament would glass FRP tubes.

Section 3
Mechanical Properties of FRPs
The performance of any engineering material in a specific 2500
application is dependent on its mechanical properties, Steel
durability, and cost. This section focuses on the mechanical ISOROD CFRP
ISOROD GFRP
2000
properties of FRPs, including the stress-strain response, and NEFMAC GFRP
NEFMAC CFRP
other properties such as creep, fatigue, fracture, and bond. NEFMAC AFRP
Stress [MPa]

TM
Leadline CFRP
1500
GENERAL
1000
The mechanical properties of an FRP depend on a number
of factors including: 500
• the relative proportions of fibre and matrix;
• the mechanical properties of the constituent materials
0
(fibre, matrix, and any additives); 0 1 2 3
• the orientation of the fibres within the matrix; and
Strain [%]
• the method of manufacture.
Figure 3-1 shows typical stress-strain curves for several Fig. 3-1. Typical tensile stress-strain curves for
unidirectional FRP materials. Also included in Figure 3-1 is various currently available FRP concrete
a stress-strain curve for reinforcing steel. Some commonly reinforcing products.
available FRPs used in concrete reinforcing applications,
and their respective properties, are listed in Tables 3-1 and Table 3-3 provides a comparison between various types of
3-2. FRPs and conventional reinforcing materials for concrete.

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

From this data it is evident that both glass and aramid FRPs comparable to, or even higher than, steel in some cases.
have moduli that are considerably less than steel in the pre- Also evident from the data is the fact that FRPs have
yield zone, but that carbon FRPs have moduli that are ultimate strengths that can be many times greater than steel.

Table 3-1. Selected Properties of Typical Currently Available FRP Reinforcing Products
Diameter Area Tensile Strength Elastic Modulus
Reinforcement Type Designation
[mm] [mm2] [MPa] [GPa]
Deformed Steel #10 11.3 100 400* 200
V-ROD CFRP Rod 3/8 9.5 71 1431 120
V-ROD GFRP Rod 3/8 9.5 71 765 43
NEFMAC GFRP Grid G10 N/A 79 600 30
NEFMAC CFRP Grid C16 N/A 100 1200 100
NEFMAC AFRP Grid A16 N/A 92 1300 54
LEADLINETM CFRP Rod Round 12 113 2255 147
* specified yield strength

Table 3-2. Selected Properties of Typical Currently Available FRP Strengthening Systems*
Weight Thickness Tensile Tensile Elastic Strain at Failure
FRP System Fiber Type
[g/m2] [mm] Strength [MPa] Modulus [GPa] [%]
Fyfe Co. LLC [www.fyfeco.com]
Tyfo SEH-51 Glass 930 1.3 575 26.1 2.2
Tyfo SCH-35 Carbon -- 0.89 991 78.6 1.3
Mitsubishi [www.mitsubishichemical.com]
Replark 20 Carbon 200 0.11 3400 230 1.5
Replark 30 Carbon 300 0.17 3400 230 1.5
Replark MM Carbon -- 0.17 2900 390 0.7
Replark HM Carbon 200 0.14 1900 640 0.3
Sika [www.sika.com]
Hex 100G Glass 913 1.0 600 26.1 2.2
Hex 103C Carbon 618 1.0 960 73.1 1.3
CarboDur S Carbon 2240 1.2-1.4 2800 165 1.7
CarboDur M Carbon 2240 1.2 2400 210 1.2
CarboDur H Carbon 2240 1.2 1300 300 0.5
Degussa Building Systems [www.wabocorp.com]
MBrace EG 900 Glass 900 0.35 1517 72.4 2.1
MBrace CF 530 Carbon 300 0.17 3500 373 0.94
MBrace AK 60 Aramid 600 0.28 2000 120 1.6
* Additional information can be obtained from the specific FRP manufacturers

Table 3-3. Comparison of Typical Approximate Properties for Reinforcing Materials for Concrete¥
Steel Steel GFRP CFRP AFRP
Property
Rebar Tendon Rebar Tendon Tendon
Tensile Strength (MPa) 483-690 1379-1862 517-1207 1200-2410 1200-2068
Yield Strength (MPa) 276-414 1034-1396 N/A N/A N/A
Tensile Elastic Modulus (GPa) 200 186-200 30-55 147-165 50-74
Ultimate Elongation (%) >10 >4 2-4.5 1-1.5 2-2.6
Compressive Strength (MPa) 276-414 N/A 310-482 N/A N/A
CTE* (10-6/˚C) 11.7 11.7 9.9 0 -1--0.5
Specific Gravity 7.9 7.9 1.5-2.0 1.5-1.6 1.25
¥
FRP materials are continually being developed with better properties. The properties given are circa 2000.
* coefficient of thermal expansion (CTE)

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Table 3-4. A qualitative comparison of the three main types of FRPs


Criterion Fibre Type
Carbon Aramid Glass
Tensile Strength Very Good Very Good Very Good
Modulus of Elasticity Very Good Good Adequate
Long Term Behaviour Very Good Good Adequate
Fatigue Behaviour Excellent Good Adequate
Bulk Density Good Excellent Adequate
Alkaline Resistance Very Good Good Adequate
Price Adequate Adequate Very Good

Modulus of Elasticity expression, which gives the tensile strength of the FRP in
For unidirectional FRP materials, the greatest strength and terms of the strengths of the fibres and the matrix:

σ frp ,ult = σ ' f V f + σ m,ult (1 − V f )


stiffness are achieved when the composite is loaded in
tension in the direction of the fibres. In this case, the elastic (Eq. 3-2)
modulus of the FRP, Efrp, can be approximately expressed in
terms of the elastic moduli of the component materials, Em However, if the fibre volume fraction is large, then the
for the matrix and Ef for the fibres, and their respective fibres carry the vast majority of the load and failure of the
volume fractions, Vm and Vf. This is done through an matrix is not critical. In this case, load is transferred to the
equation known as the rule of mixtures: fibres, which continue to carry the load, until their failure

E frp = E mVm + E f V f = (E f − E m )V f + E m
strain is reached. This condition is described by:
(Eq. 3-1)
σ frp ,ult = σ f ,ultV f (Eq. 3-3)
The above expression is valid only in the direction of the
fibres for unidirectional composites, and the modulus of If the failure strain of the matrix is greater than the failure
elasticity perpendicular to the fibres is generally very much strain of the fibres, as shown in Figure 3-3, and the fibre
lower. Refer to Tables 3-1 and 3-2 for listings of elastic volume fraction is small, then failure of the FRP is
properties for a variety of unidirectional FRP materials in prevented when the fibres fail and the ultimate strength of
tension. the FRP is described by:
The compressive elastic modulus is generally less than
that achieved in tension. Values of the compressive elastic
modulus are typically about 50-80% of those determined
σ frp ,ult = σ m ,ult (1 − V f ) (Eq. 3-4)
from tensile testing, depending on the type of FRP under
consideration. However, if the fibre volume fraction is large, then the
transfer of load from the fibres to the matrix at initial fibre
Strength fracture is large and the FRP fails. This condition is
The strength of unidirectional FRP materials when loaded in approximately described by:

σ frp ,ult = σ f ,ultV f + σ ' m (1 − V f )


the fibre direction is dependent on whether the applied load
is tensile or compressive, with most FRPs being vastly more (Eq. 3-5)
effective in tension (hence their common use as tensile
reinforcement for concrete). For most applications of FRPs in civil engineering
The response of an FRP material in tension is applications, the fibre volume fraction, Vf, is greater than
dependent largely on the failure strains of the two about 0.1 and is considered large.
component materials, and two possible cases of behaviour The tensile strength perpendicular to the fibres is much
demand consideration. Figures 3-2 and 3-3 show the less than that in the fibre direction and depends on a range
potential scenarios for failure strains of the fibres and of factors. Since FRPs are rarely loaded in this manner in
matrix, and provide insight into the failure behaviour of civil engineering applications, no further discussion of
FRP materials. transverse loading is included here.
If the failure strain of the matrix, εm,ult, is less than the When loaded in compression, the FRP’s ultimate
failure strain of the fibres, εf,ult, as shown in Figure 3-2, and strength is less than that achieved in tension, and depends
the fibre volume fraction, Vf, is small (say less than about on a number of factors including the fibre type, the matrix
0.10), then failure of the FRP is governed by the matrix. properties, and the matrix-fibre interface strength. The
This condition is described by the following approximate ultimate compressive strength of FRPs can be reached due
to fibre micro-buckling, transverse tensile failure in the

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

matrix, or shear failure. Axial compressive strengths for Research into the fatigue behaviour of FRP composites
uniaxial FRP materials loaded in the fibre direction are is ongoing, but the following general comments can be
typically about 55%, 20%, and 78% of the axial tensile made. Carbon FRPs display outstanding fatigue behaviour.
strength for glass, aramid, and carbon FRPs respectively. This has been attributed to the fact that carbon fibres have a
Aramid fibres perform particularly poorly in compression, very high stiffness, which limits the strains experienced by
and, as a consequence, FRP strength is commonly neglected the polymer matrix component, and prevents matrix
when acting in compression when used as reinforcement for cracking and breakdown of the matrix-fibre interface bond,
concrete. In some cases however, as in the case of thus preventing failure. Tensile fatigue tests conducted on
pultruded FRP structural sections in compression or unidirectional carbon/epoxy FRP strands have indicated that
bending, the compressive strength of FRPs is relied upon to CFRP can sustain much greater mean stresses and stress
carry load. amplitudes than steel. Glass fibres are considerably less
stiff, and so glass FRP matrices experience larger strains
Stress, σ during load cycling which lead to more matrix cracking and
σf,ult can eventually lead to failure. While aramid fibres have
Fibre stiffness that is intermediate between glass and carbon, so
we might expect that they display intermediate fatigue
σ’f behaviour, aramid fibres themselves are innately sensitive to
fatigue damage through a process called de-fibrillation,
which can lead eventually to fatigue failure. Figure 3-4
σm,ult shows typical fatigue life curves for carbon and glass FRPs,
where the superior fatigue behaviour of carbon FRPs is
Matrix Strain, ε evident, as is the effect of fibre modulus on fatigue life.

εm,ult εf,ult
Maximum Cyclic Stress / Tensile Stress
120

Fig. 3-2. Failure strains of FRP component 100


materials when the failure strain of the matrix is
less than that of the fibre. 80

60
Stress, σ
σf,ult 40
Fibre High Modulus Carbon FRP
Intermediate Modulus Carbon FRP
20 Low Modulus Carbon FRP
E-Glass FRP
0
1 2 3 4 5 6 7 8
0 10 10 10 10 10 10 10 10
σm,ult
Number of Cycles to Failure
σ’m Matrix
Strain, ε Fig. 3-4. Fatigue-life curves for FRPs with different
fibre types.
εf,ult εm,ult

Creep
Fig. 3-3. Failure strains of FRP component Creep is a phenomenon exhibited to varying degrees of
materials when the failure strain of the matrix is severity by virtually all engineering materials. Creep refers
more than that of the fibre. to a condition of increasing strain under a sustained
(constant) level of stress. Although carbon, glass, and
Fatigue aramid fibres display comparatively little creep themselves
Fatigue refers to the degradation or failure of a structural under most ambient conditions, FRP matrix materials are
material or element after repeated cycles of loading and visco-elastic (they display properties of both elastic solids
unloading. Most unidirectional FRP materials used in civil and viscous fluids) and so FRP materials will creep under
engineering applications display good fatigue behaviour in sustained load. The amount of creep exhibited by a
comparison with steel, although some FRP materials particular FRP will depend primarily on the fibre volume
(carbon FRPs in particular) display superior fatigue fraction and the orientation of the fibres with respect to the
characteristics. applied loads. In addition, both temperature and moisture

11
ISIS Canada Educational Module No. 2: FRP Composites for Construction

can have significant effects on the creep behaviour of Creep Rupture (Stress-Corrosion)
polymers. However, for most unidirectional FRP materials Some types of fibres (glass in particular) are susceptible to a
used in civil engineering applications creep is not normally failure mode known as creep rupture (sometimes called
a significant concern, provided that the sustained stress in stress-corrosion). In this mode of failure, the fibres fracture
the FRP is limited. Thus, ISIS Canada conservatively under sustained load levels that are much less than the
recommends that the sustained stress levels in unidirectional failure stress of the composite observed under static testing.
FRP structural components be limited to the following Because of the susceptibility of glass fibres, and hence glass
percentages of the FRP’s design ultimate strength: FRPs, to creep rupture, stress levels in glass FRPs are often
• Glass FRP, 20% severely limited under sustained loads, to less than 20 or
• Aramid FRP, 30% 25% of the static tensile strength (see the stress limits
• Carbon FRP, 50% quoted previously).

Section 4
Environmental Durability of FRPs
The mechanical properties of engineering materials are of the mechanical properties of FRP components. Elevated
obviously of paramount importance to structural designers temperatures can also have important effects on the long-
contemplating their use. However, equally important in the term durability of FRP materials, as discussed below. Low
examination of potential materials and systems for use in temperatures are not generally a concern for polymer matrix
infrastructure applications are environmental and durability FRPs in most structural applications, except in those rare
considerations. Exposure to a variety of adverse conditions instances where extremely low (cryogenic) temperatures
can significantly alter the mechanical performance of FRP result in embrittlement of polymer matrix materials.
materials, and failure to consider the effects of factors such Temperature effects on FRPs are varied and complex,
as temperature, moisture, ultra-violet radiation, assorted and research into the effects of temperature on FRP
chemicals, and fire can lead to unsatisfactory performance. materials is ongoing. As such, an exhaustive discussion of
This section briefly examines a number of important factors this topic is avoided here. However, the following is a list
which have the potential to influence the durability of FRP of issues of which the reader should have a general
materials used in construction. It is important to remain awareness when considering the use of FRPs in a potential
cognizant of the fact that all engineering materials are structural application:
sensitive to different environments in different ways. The • high temperatures will increase the rate of creep for
factors listed in this section should in no way be construed FRP materials;
as issues being unique to FRPs. In fact, FRPs offer • higher temperatures will increase the rate of FRP
significant durability advantages over conventional degradation due to chemical attack or moisture ingress;
materials such as steel in many cases. • differential thermal expansion (between the fibres and
The durability of FRP reinforcing bars in concrete is a the matrix, or between the FRP and the substrate in
complex topic and research in this area is ongoing. Readers cases where FRP is bonded to concrete, steel, or timber)
seeking additional information on the durability of FRP may lead to the development of thermal stresses which
materials are encouraged to consult ISIS Educational could damage the matrix-fibre interface or the interface
Module #8, also available from ISIS Canada at between the FRP and the substrate. This is because the
www.isiscanada.com. coefficient of thermal expansion (CTE) of FRPs vary
depending on type and may be significantly different
Temperature than the substrate materials (refer to Table 3-2); and
Temperature is an extremely important factor in the design • thermal cycling, and the resulting repeated thermal
and use of FRP materials for infrastructure. At elevated stresses that are induced, can cause damage to FRP
temperatures, polymer materials will decompose, or in some materials through matrix cracking and fibre fracture,
cases, burn. The operating temperature to which an FRP which can exacerbate problems due to moisture ingress
component is subjected in service is therefore limited to and/or chemical attack.
about 20˚C less than the glass transition temperature (GTT),
for an epoxy resin, or the heat distortion temperature (HDT), Moisture
for a vinylester or polyester. At these temperatures, major Almost all polymers, if placed in a wet environment, will
changes are observed in the mechanical properties of the absorb moisture from their surroundings until their
polymer matrix materials which lead to a rapid deterioration saturation point is reached. The amount of moisture

12
ISIS Canada Educational Module No. 2: FRP Composites for Construction

absorbed and the effects of this absorption on the paint which matches the substrate concrete and effectively
mechanical performance of the composite will vary “hides” the repair material.
depending on the FRPs’ composition and properties. It is
currently believed that moisture ingress in FRP composites Alkali Effects
generally occurs in the matrix region close to the fibres (by FRP materials are increasingly being used as internal
capillary action) and subsequently degrades the properties of reinforcement for concrete structures in an attempt to
the matrix while also damaging the surface of the fibres. address the corrosion problems that are commonly
Thus, for unidirectional composites, the tensile strength of encountered when concrete is reinforced with conventional
the FRP, which is less dependent on matrix properties, is steel rebars. The environment inside healthy concrete is
relatively unaffected by moisture uptake, while the matrix highly alkaline (the pH level is generally between 12 and
dominated properties, such as shear and compressive 13.5), and this can be a concern for glass fibre materials,
strength, can be severely degraded. Aramid fibres are which suffer from reduced toughness and strength through
particularly sensitive to the effects of moisture since the alkalinity-induced embrittlement. As a result, GFRP rebars
fibres themselves are known to absorb moisture and swell, are often manufactured using alkali-resistant polymer
subsequently causing matrix cracking and resulting in the matrices. While there remains some uncertainty as to the
development of internal stresses. Thus, aramid fibres have effects of alkalis on glass FRP rebars, it is generally agreed
recently fallen out of favour in applications where moisture that GFRP can be used for reinforcement of concrete
is a potential concern. provided that sustained (service) stresses are limited (as
It is worth noting that degradation of the mechanical mentioned previously) to account for potential degradation.
properties of FRPs due to moisture will reach some
maximum level when the polymer matrix reaches its
saturation point. Once this point is reached, no further Fire
reduction in mechanical properties is expected. This All polymer resins will burn when subjected to sufficiently
behaviour is fundamentally different than the deterioration high temperatures, and thus fire can be a serious concern for
of steel due to moisture, where corrosion will continue until FRP materials and for structures which incorporate them.
the metal has corroded completely. Polymers commonly used as matrices in infrastructure FRPs
are all combustible and generally release large quantities of
dense, black, and sometimes toxic and/or corrosive smoke.
UV Radiation Thus, the potential consequences of fire must be considered
Ultra-violet (UV) radiation can degrade FRP materials. during the design process for any structure incorporating
Aramid fibres are known to be particularly sensitive to UV FRP materials. Various options exist for fire protection of
radiation, while both carbon and glass fibres are resistant to FRP materials through the use of intumescent coatings, fire
UV light. In addition, most polymer matrices will degrade insulation, matrix additives, and ceramic paint, although all
slightly due to UV radiation. involve trade-offs in terms of cost, ease of application, and
Degradation due to UV light can be prevented through effects on the mechanical properties of the FRP. Research
the use of various matrix additives, the application of a is ongoing in this area.
pigmented gel coat on the exterior of an FRP, or by painting
the FRP with an opaque paint. For instance, in most field
applications of concrete strengthening by externally-bonded
FRP plates or sheets, the FRP is finished with a UV resistant

Section 5
Applications of FRPs in Civil Engineering
Because of the tremendous variety in types, shapes, and appear each year. For detailed and current information, the
properties of FRP materials, there is an enormous variety of reader is referred to www.isiscanada.com.
applications in which FRPs can be effectively used in
structural engineering and infrastructure applications. This
ALL-FRP STRUCTURES
section briefly outlines some of the more common
applications of FRPs in the civil infrastructure. The reader
should remember that the use of FRP materials in structures The most obvious potential use of FRPs in structures is to
is a rapidly evolving discipline, and many new applications fabricate entire structures, or specific structural components,
out of FRP. This is most easily and inexpensively

13
ISIS Canada Educational Module No. 2: FRP Composites for Construction

accomplished using pultruded FRP structural sections which major design issues which require consideration in the
can be manufactured relatively easily and inexpensively design of FRP-reinforced concrete members include: the
from glass FRP. All-FRP structures are becoming more fact that FRPs are linear-elastic to failure, unlike steel which
common for small-scale structures such as pedestrian exhibits a well-defined yield plateau, and the fact that FRP
bridges, utility poles, parking garage stairwells, and reinforcements generally have elastic moduli that are less
platforms in marine and offshore structures. Figure 5-1 than steel, so serviceability requirements often govern the
shows a short-span all-FRP road bridge in the United States. design. Figure 5-3 shows glass FRP reinforcement installed
In addition to all-FRP structures, FRPs have also been in a concrete bridge deck in Quebec (shown just prior to
used to construct specific structural components such as placement of the concrete).
bridge deck panels (Figure 5-2) and girders, cable-stayed
bridge support cables, blast panels, space trusses, modular
residential building systems, marine sheet piling, and
ground anchors.

Fig. 5-1. A short-span all-FRP road bridge. Fig. 5-3. Glass FRP reinforcing bars placed in a
concrete bridge deck immediately prior to
placement of the deck concrete.

FRP tendons have also been successfully used as both


internal and external prestressed reinforcement for concrete
beams, slabs, and bridge decks. However, glass FRP should
not be used as prestressed reinforcement because of its
susceptibility to creep-rupture, nor should aramid FRP
because of its sensitivity to moisture-induced swelling.
A complete discussion of the design and analysis of
concrete members incorporating FRP reinforcing materials
can be found in ISIS EC Module 3, which is readily
available from ISIS Canada.
Fig. 5-2. A section of a glass FRP bridge deck
panel being tested under a simulated vehicle REPAIR AND REHABILITATION
wheel-load in a structural engineering research
laboratory. As stated earlier, after decades of neglect and overuse, the
North American infrastructure is crumbling. Many agencies
FRP-REINFORCED CONCRETE have recently suggested that expenditures in the trillions of
dollars are now required to bring our infrastructure up to an
Because FRP materials will not corrode electrochemically, acceptable level. There are many factors contributing to the
FRP bars, rods, and tendons are increasingly being used in unsatisfactory state of our infrastructure, including:
lieu of conventional reinforcing steel for internal • deterioration due to corrosion;
reinforcement of concrete. Both glass and carbon FRP • environmental degradation;
rebars and reinforcing grids have been used successfully as • greater traffic volume and increased vehicle weights;
internal reinforcement in concrete beams and slabs, as have • updated design loads and seismic requirements; and
various hybrid FRP grids composed of both glass and • vehicle collision, fire, and vandalism.
carbon fibres. Research and field applications of FRP During the past fifteen years or so, a number of
rebars in concrete bridge decks have indicated that these preservation, rehabilitation, and strengthening techniques
materials perform well in the harsh Canadian climate. The which use FRP materials have emerged for use with a

14
ISIS Canada Educational Module No. 2: FRP Composites for Construction

variety of concrete, steel, aluminum, masonry and timber


structures. Several are discussed below.

Concrete Structures
FRP materials are becoming increasingly popular for repair
and strengthening of reinforced concrete structures, and
FRPs are now materials of choice for flexural, shear, and
axial strengthening of reinforced concrete members. In this
application, FRP plates or sheets are bonded to the exterior
of reinforced concrete members using the wet lay-up
procedure with an epoxy resin/adhesive. The FRP sheets or
plates are generally bonded to the tension faces of flexural
elements to increase their bending capacity, or to their side
faces to increase the shear capacity (Figure 5-4). In
addition, FRP sheets can be applied circumferentially
around reinforced concrete columns to provide confining
reinforcement which has been shown to increase both their
strength and ductility (Figure 5-5). A much more complete
discussion into the use of FRPs for strengthening concrete
structures is provided in ISIS EC Module 4, which is also
readily available from ISIS Canada.
Fig. 5-5. A circular concrete column being
strengthened with carbon FRP sheets.

Fig. 5-4. This concrete bridge girder has been


strengthened in shear with externally-bonded
carbon FRP sheets. The FRP was subsequently
painted with a “camouflaging” UV-resistant paint.
Fig. 5-6. Repair of welded joints in an overhead
tubular aluminum sign standard using glass FRP
Metallic Structures sheets.
Many metallic structures such as bridge girders, cranes,
hydroelectric structures, and overhead signs are also Masonry Structures
currently in need of structural upgrading, and FRP materials Many aging masonry structures, built long before current
are beginning to see use in these applications due largely to design loads and guidelines were formulated, are now
the ultra high-modulus fibres that are now available. By considered structurally inadequate in a number of respects
externally bonding FRP sheets or wraps to the exterior of (commonly with respect to seismic loading). Externally-
metallic structures, their flexural, shear, axial, and joint bonded FRP reinforcements can be used to increase both the
strengths can be significantly enhanced. Some specific strength and ductility of masonry walls and columns for
applications have included glass FRP wraps for the repair of both in-plane and out-of-plane shear and flexural behaviour.
damaged welds in aluminum overhead signs (Figure 5-6), An example of a typical FRP strengthening application on a
and the use of ultra-high modulus carbon FRP sheets for masonry wall is shown in Figure 5-7, where transparent
increasing the flexural capacity of steel bridge girders. glass FRP sheets have been used to improve the in-plane
behaviour of a traditional clay brick masonry wall.

15
ISIS Canada Educational Module No. 2: FRP Composites for Construction

Timber Structures Seismic and Blast Retrofit


FRPs have successfully been used to strengthen existing In addition to repair and strengthening applications
timber structures such as historic buildings and covered incorporating FRPs as outlined in the previous section,
timber bridges (Figure 5-8). This is commonly done to externally bonded FRP wraps, plates, and sheets have been
increase the flexural capacity of a beam or girder, and can successfully used to improve the performance of reinforced
be accomplished by external bonding or near surface concrete and masonry structures subject to the dynamic
mounting (NSM). In external bonding, FRP plates or sheets loads resulting from seismic and/or blast loading. These
are bonded to the exterior of the timber member using a advanced applications involve similar techniques as those
structural adhesive (normally an epoxy or phenolic resin), as discussed previously for repair and strengthening. The most
shown in Figure 5-9. This application is similar to concrete common seismic and blast strengthening applications
or steel strengthening applications of FRPs. In the NSM involve FRP plating or wrapping of concrete or masonry
technique, small grooves or troughs are cut into the tension walls and columns to increase both load carrying capacity
face of the member and an FRP bar or plate is inserted into and ductility.
the groove along with a structural adhesive grout. NSM is
particularly attractive in applications where it is desired that
the aesthetics of the original structure be maintained.

Fig. 5-9. A historic timber bridge which has been


strengthened with carbon FRP materials applied to
the underside of selected beams.

HYBRID FRP/CONCRETE MEMBERS

Recently, a number of hybrid FRP/concrete structural


systems have been developed for use as structural members.
Many variations on this general theme have been proposed,
Fig. 5-7. This traditional clay brick masonry wall although most of these systems involve concrete and FRPs
has been strengthened (in a laboratory setting) in combination and are fabricated in such a way as to place
with externally-bonded glass FRP sheets for the concrete in the compressive region of the cross-section
improved in-plane behaviour. while the FRP is concentrated in the tension region. These
innovative structural systems can thus be a highly efficient
use of materials; they can be very light, and are presumably
maintenance-free since no corrosion is expected to occur.
Hybrid members can be used as supporting elements in
buildings and as girders for bridges, as well as for concrete-
filled FRP piles for bridge and marine structures (Figure
5-10).
Another interesting application of FRPs which results
in a hybrid member is FRP stay-in-place formwork. In
these applications the concrete formwork is fabricated from
FRP and remains in place after the concrete has cured. If
the FRP can be made to act in a composite manner with the
hardened concrete, then the FRP can be used as the tensile
reinforcement for concrete slabs and beams. Concrete-filled
Fig. 5-8. This historic timber bridge which has FRP tubes are an example of the stay-in-place formwork
been strengthened with carbon FRP materials.

16
ISIS Canada Educational Module No. 2: FRP Composites for Construction

concept, where the concrete is placed inside a precured FRP materials and smart structures. Smart structures are those in
tube (usually fabricated using the filament winding process). which sensors are installed to continuously monitor the
Once the concrete has hardened, the FRP tube formwork performance of the structure throughout its lifetime.
provides both tensile and confining reinforcement to the Recently, FRP materials have been developed which include
concrete. An application of concrete-filled FRP tubes is fibre-optic sensors (FOS) as part of their internal structure.
shown in Figure 5-10. These FOS can be used to measure variations in strain and
temperature within the structure itself, and can provide
information to engineers on its short and long-term
performance. These materials can be considered an
emerging technology, although several smart structures have
already been built in Canada and are currently under
observation. Smart structures and materials will
undoubtedly become more important and widespread in the
future. Figure 5-11 gives an example of a smart structure in
Canada: the Taylor Bridge near Winnipeg. More
information on smart structures is available from the ISIS
Canada website (www.isiscanada.com).

Fig. 5-10. An example of hybrid FRP/concrete


members, concrete-filled FRP tubes act dually as
foundation piles and bridge piers in this
application.

THE FUTURE Fig. 5-11. The Taylor Bridge near Winnipeg,


Manitoba, seen here under construction, is one of
The future holds unlimited promise for the use of FRPs in Canada’s first smart structures.
structural engineering applications. One of the most
exciting recent advances is the development of smart

Section 10
References and Additional Information
Additional information on the use of FRP materials can be obtained in various documents available from ISIS Canada:

• ISIS Design Manual No. 3: Reinforcing Concrete Structures with Fiber Reinforced Polymers.
• ISIS Design Manual No. 4: Strengthening Reinforced Concrete Structures with Externally-Bonded Fiber Reinforced
Polymers.
• ISIS Design Manual No. 5: Prestressing Concrete Structures with FRPs.
• ISIS Canada Specifications for Product Certification of Fibre Reinforced Polymers (FRPs) as Internal Reinforcement in
Concrete Structures
• ISIS Educational Module 1: Mechanics Examples Incorporating FRP Materials.
• ISIS Educational Module 3: An Introduction to FRP-Reinforced Concrete.
• ISIS Educational Module 4: An Introduction to FRP-Strengthening of Concrete Structures.
• ISIS Educational Module 6: Application and Handling of FRP Reinforcements for Concrete.

17
ISIS Canada Educational Module No. 2: FRP Composites for Construction

• ISIS Educational Module 8: Durability of FRP Composites for Construction.

The following publications have been used in the preparation of this module and can be consulted for a more complete
discussion of the various topics presented herein:

• CSA 2002. CAN/CSA-S806-02: Design and Construction of Building Components with Fibre Reinforced-Polymers.
Canadian Standards Association, Ottawa, ON.
• CSA 2005. CAN/CSA-S6-05: The Canadian Highway Bridge Design Code (CHBDC). Canadian Standards Association,
Ottawa, ON.
• ACI 2003. ACI 440.1R-03: Guide for the design and construction of concrete reinforced with FRP bars. American
Concrete Institute, Farmington Hills, MI.
• ACI 2002. ACI 440.2R-02: Guide for the design and construction of externally bonded FRP systems for strengthening
concrete structures. American Concrete Institute, Farmington Hills, MI.
• ACI 1996. ACI 440R-96: State-of-the-art report on fiber reinforced plastic reinforcement for concrete structures.
American Concrete Institute, Farmington Hills, MI.
• Teng, J.G., Chen, J.F., Smith, S.T., and Lam, L. 2002. FRP strengthened concrete structures. Wiley.
• Hollaway, L.C., and Head, P.R. 2001. Advanced polymer composites and polymers in the civil infrastructure. Elsevier.
• Hollaway, L.C. 1990. Polymers and polymer composites in construction. Thomas Telford Ltd., London, UK.
• Chawla, K.K. 1998. Composite materials: Science and engineering. Springer.
• ICE 2001. FRP composites: Life extension and strengthening of metallic structures. Institution of Civil Engineers,
Design and practice guides. Thomas Telford Ltd., London, UK.

Further information on field applications of FRPs in various types of structures is available from a number of sources,
including:

• ACI Special Publication SP-215-9. Field Applications of FRP Reinforcement: Case Studies. Published by the American
Concrete Institute, 2003.
• ASCE Journal of Composites for Construction. Published by the American Society of Civil Engineering, 1997-2004.

Notation
Ef Elastic modulus of the fibres (MPa)
Efrp Elastic modulus of the FRP (MPa)
Em Elastic modulus of the matrix (MPa)
Vf fibre volume fraction
Vm matrix volume fraction
εf,ult failure strain of the fibres
εm,ult failure strain of the matrix
σfrp,ult ultimate tensile strength of a unidirectional FRP in the direction of the fibres (MPa)
σ’f stress in the fibres at failure (MPa)
σ’m stress in the matrix at failure (MPa)
σf,ult ultimate tensile strength of the fibres (MPa)
σm,ult ultimate tensile strength of the matrix (MPa)

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Appendix A:
Suggested Laboratory
The following laboratory procedure is given as an example • it forces students to consider and understand important
of a materials laboratory that could be given in conjunction mechanics concepts such as elasticity, plasticity, and
with an undergraduate course on engineering materials or ductility;
mechanics of materials, and that includes tests on both steel • it vividly illustrates the concept of ductile versus brittle
and FRP materials. Given the wide variety of laboratory and materials, and demonstrates the need for thoughtful
testing facilities available at various Canadian universities, consideration of materials’ behaviour during
this laboratory is given primarily as an example for engineering design; and
professors of what can be done using FRP materials to • it exposes students to the state-of-the-art in civil
increase laboratory impact and student understanding of engineering materials and thus increases student
important materials concepts. enthusiasm for the course content, subsequently, in
Inclusion of FRP materials into traditional strength of many cases, increasing student participation and effort.
materials laboratories is advantageous for a number of The laboratory presented herein suggests several
reasons, including: possible options for tensile test configurations for FRP
• it introduces students to a new and innovative material materials. It is important to recognize that the laboratory
which is gaining acceptance within the civil procedures can be adapted to include the use of any specific
engineering industry; type of FRP reinforcement, and the specific configurations
• it increases student understanding of the fundamental suggested herein have been used only as an example.
materials concepts and assumptions used in structural
design and analysis;

Caution:
FRP Materials
FRPs are linear elastic materials. As such, these materials specific failure modes to be expected when testing FRP
do not display the yielding behaviour observed when testing materials, and that appropriate safety precautions be
steel and they provide little warning prior to failure. It is taken in addition to those precautions that are normally
extremely important that instructors, students, laboratory enforced.
demonstrators, and technical staff be made aware of the

19
ISIS Canada Educational Module No. 2: FRP Composites for Construction

A Comparative Study of Fibre Reinforced


Polymers (FRPs) and Steel under Axial
Tension
OVERVIEW theoretical and observed results, and a comparison of
the behaviour of the data obtained by the other lab
groups.
This laboratory is intended to increase students’
6. A conclusion in which the major points of interest
understanding of the behaviour of both steel and fibre
from the above sections are highlighted. The focus in
reinforced polymers (FRPs) in tension. During the
the conclusion should be on the consequences of the
laboratory, tensile tests will be carried out on both steel and
observed behaviour on the practical design of
FRP test specimens in order to ascertain their characteristic
engineering structures.
stress-strain behaviour and material properties. This
7. A list of references. All tests referenced during the
laboratory illustrates the following important concepts:
course of the laboratory project should be listed using
1. the overall tensile behaviour of both steel and FRP;
an accepted referencing format.
2. concepts of stress, strain, and elastic modulus;
3. concepts of elastic and inelastic material behaviour;
4. use of the elastic modulus to calculate stresses and OBJECTIVES
strains for linear-elastic materials;
5. yield strength, plasticity, and the behaviour of steel The objective of this laboratory can be summarized as
before and after yielding; follows:
6. ultimate strength of different engineering materials; 1. To observe and develop stress-strain relationships for
and both steel and FRPs in tension.
7. characteristic brittle failures observed for FRP 2. To determine the elastic modulus of both steel and FRP
materials versus the more ductile failures commonly materials.
observed with steel. 3. To define the proportional limit and the yield strength
The class will be divided into groups of four students of steel.
each, each group being responsible for the analysis their 4. To define the ultimate stress and strain for both steel
own data obtained during two tensile tests, one on FRP and and FRP in tension.
the other on steel, and for the submission of a single 5. To observe the effects of inelastic behaviour.
laboratory report. All data obtained during the testing 6. To compare the overall stress-strain behaviour and
performed by each group will be made available to all other failure modes of ductile materials versus those of brittle
groups for use in writing their laboratory reports. materials.

Laboratory Report Apparatus

The laboratory report should consist of the following: The following are required for this laboratory:
1. A title page giving the group name and number. • Universal Testing Machine
2. An abstract, briefly stating the purpose and procedure • Axial Extensometer
of the lab and the major conclusions drawn. • X-Y plotter
3. An introduction providing information on the • Digital Calipers/Digital micrometer
materials used, testing setup, instrumentation, • Gauge Block
procedures, etc. • Standard ASTM Steel Specimen
4. A calculations and analysis section detailing all
• Standard ASTM FRP Specimen (or alternative FRP
calculations performed for the laboratory. Where a specimen depending on testing apparatus being used)
calculation has been performed more than once only a
sample calculation should be provided.
5. An experimental results and discussion section, PROCEDURES
summarizing the test results obtained for all specimens
tested. This section should include photographs The Universal Testing Machine will be used to perform the
(where available) and plots showing specimen tensile tests on the specimens (refer to Figure A.1 below). A
behaviour along with a thorough comparison of controlled tensile load will be applied to the specimens by

20
ISIS Canada Educational Module No. 2: FRP Composites for Construction

means of a movable crosshead. During the test, tensile load steels with minimal alloy elements, and are commonly used
and elongation in the test specimens will be recorded using in different structural applications. Typical material
a load cell and an axial extensometer, which will measure properties for construction-grade carbon steel are given in
the elongation of the specimens over a specific gauge Table A.1. The steel specimen for this laboratory can
length. Either a constant rate of change for load or a consist of a machined bar (in accordance with ASTM
constant rate of change for displacement may be selected. Standard E8-91) or a section of conventional reinforcing
Constant rate of change for displacement will be used steel (in accordance with ASTM Standard A370-97),
herein. Electronic signals from the load cell and depending on the availability of testing equipment and
extensometer will be input into an X-Y plotter and a specimen grips (refer to Figure A.2).
computer data-logging system in order to allow
construction of a load-deformation curve and to prepare Fibre Reinforced Polymer (FRP)
data for analysis by the students. Unidirectional carbon, glass, and aramid fibre reinforced
polymers are gaining acceptance as structural materials in a
variety infrastructure applications. These materials
demonstrate outstanding strength and stiffness
characteristics when loaded longitudinally in the direction
Movable of the fibres. Glass FRPs are relatively inexpensive and are
Crosshead
therefore the most commonly used. Recently, glass FRPs
Load
have emerged as cost-effective, non-corrosive reinforcing
Frame materials for concrete. Carbon fibres, which are more
Test
Specimen costly but have a higher modulus of elasticity and slightly
better durability and fatigue characteristics, are emerging as
prestressing materials for concrete. Both carbon and glass
Stationary FRPs are currently being used in externally-bonded FRP
Crosshead
strengthening applications for rehabilitation and
strengthening of reinforced concrete structures.
This laboratory can be performed either with FRP rebar
specimens or with FRP coupon specimens, depending on
the availability of the required grips in the testing laboratory
(refer to Figure A.2). FRP bar and coupon specimens are
shown schematically in Figure A.2. Coupon specimens
Hydraulic should be prepared in accordance with ASTM D3039-98.
Cylinder FRP bar specimens are extremely weak in the transverse
direction, and hence they cannot be tested using standard
steel rebar testing grips. FRP bar specimens should be
prepared by anchoring the ends of the bar specimen into
Figure A.1: Schematic of the Dynamic Testing steel tubes using a high strength concrete grout. The steel
Machine tubes can then be effectively gripped using standard
reinforcing steel testing grips. ASTM standards for this test
Materials method do not currently exist. Additional guidance on the
preparation of FRP bar tensile specimens can be obtained
Steel from ISIS Canada or Committee 440 of the American
A common structural steel grade, such as ASTM A572, Concrete Institute. Typical material properties for glass and
CSA G40-21 350 W, or other available construction-grade carbon FRP materials are given in Table A.1.
steel will be tested. These materials are generally carbon

Table A.1 – Typical mechanical properties of steel and FRP materials


Material Yield Stress Ultimate Stress Elastic Modulus Strain at Failure
(MPa) (%)
Carbon Steel 250-450 450-700 MPa 200 GPa 7-15
Glass FRP Bar N/A 517-1207 MPa 30-55 GPa 2-4.5
Carbon FRP Bar N/A 1200-2410 MPa 100-165 GPa 1-1.5
Glass FRP Coupon N/A 530-750 N/mm width 25-35 kN/mm width 2.1-2.2
Carbon FRP Coupon N/A 595-3920 N/mm width 70-360 kN/mm width 0.3-1.7

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

End
Tabs

FRP
Bar

OR OR

Steel
Pipe

Cement
grout

Machined Steel
Steel Bar Rebar FRP Coupon with FRP Bar with Steel
Anchorage Tabs Pipe Anchor Ends

Figure A.2: Typical Test Specimens


Testing Procedure
Steel Specimen
1. Using the digital calipers, measure the specimens to 4. With the help of the instructor, mount the steel
determine the cross-sectional area at 3 locations within specimen in the load frame and affix the extensometer
the gauge section. Record the average area of each to the specimen. Loading of the machine, and setting
specimen in units of mm2 to an accuracy of +/- of scales and the rate of loading/deformation should be
0.01mm2. If FRP coupons are being tested (as opposed done by the laboratory instructor or by an experienced
to FRP bars) measure the width only, since properties technician. Record the loading/deformation rate for
for these materials are generally quoted in N/mm of the specimen.
sheet width. 5. With the help of the instructor or technician, ZERO the
2. Using the gauge block, lightly punch two marks on the load applied to the specimen by adjusting the position
steel specimen. These will be used to measure the of the Dynamic Testing Machine’s hydraulic ram.
elongation of the gauge length manually after the axial Also, adjust the X-Y plotter so that it indicates zero
extensometer is removed. Measure the exact gauge force and deformation in the test specimen.
length of the steel using the digital calipers, and record 6. Load the specimen in tension up to 80% of the
this measurement on your data sheet. expected yield load and reverse the direction of
3. Using the material properties given for the specific steel loading.
and FRP specimens being tested (consult the laboratory 7. Reduce the load to zero, and then reload the specimen
demonstrator): in tension until yielding is observed. Continue loading
a. Calculate the expected yielding load and the beyond yield to ascertain that the yield point has been
corresponding deformation for the steel specimen. exceeded (or if no true yielding occurs, that the
Values for 50% and 80% of the yielding load are proportional limit has been exceeded).
also required. 8. It is now required to put the specimen through an
b. Calculate the expected ultimate load and the unload-reload cycle. Reduce the tensile load to about
corresponding deformation for the FRP specimen. 50% of the yielding load. Reload the specimen again
A value for 50% of the ultimate load is also to the previously observed yielding load. Allow a little
required. more deformation to occur beyond this point to

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

establish the shape of the curve. Stop loading, turn off values/parameters for the steel specimen:
the X-Y recorder input and carefully remove the
extensometer from the specimen. • elastic modulus, Es
9. The steel specimen will now be loaded to tensile failure. • stress at proportional limit, σp
Take length measurements between the gauge marks • stress at yield point (if apparent) or at 0.2% offset
using the digital calipers at deformation increments of strain, σy
approximately 1 mm or about every 15-30 seconds. • ultimate tensile strength, σs,ult
Record these length measurements and the • stress at fracture, σs,f
corresponding load values. Watch the digital display
• percentage deformation at fracture, εs,f
closely to determine the maximum load reached. At that
• percentage reduction of cross-sectional area at fracture
point, a caliper measurement of the length between
gauge marks is to be recorded. • type and character of fracture
10. After fracture, stop the test by having the instructor turn
off the controller and remove the fractured pieces of the Using the formulae provided, determine the following
specimen from the machine. Re-align the pieces and values/parameters for the FRP specimen:
measure the final length between the gauge marks. Also
measure the final diameter at the location of fracture. • elastic modulus, Efrp
Save the pieces for sketching the mode of failure. • ultimate tensile strength, σfrp,ult
11. Remove the plot from the X-Y plotter and turn off the • estimated percentage deformation at ultimate/fracture,
plotter. εfrp,ult
• type and character of failure
FRP Specimen
12. Repeat steps 4 and 5 for the FRP specimen. Turn on the A separate tabular summary of the values for the various
X-Y plotter. quantities listed above should be made for both materials.
13. Load the specimen in tension up to 50% of the expected
ultimate load and reverse the direction of loading. REQUIRED DISCUSSION
14. Reduce the load to zero, and then reload the specimen in
tension up to 50% of the expected ultimate load. Stop
The discussion portion of your lab report should address
loading, turn off the X-Y recorder input and carefully
the following key topics:
remove the extensometer from the specimen.
1. Compare and contrast the elastic modulus of the two
15. The FRP specimen will now be loaded to rupture.
materials tested.
Watch the digital display closely to determine the
2. Compare the yield strengths and ultimate tensile
maximum load reached. Failure of the FRP specimen
strengths of the two materials tested. Did both
may be sudden and violent, with little warning.
materials yield?
Maintain a safe distance from the testing machine.
3. Compare the elastic modulus, yield strengths, and
16. After fracture, stop the test by having the instructor turn
ultimate tensile strengths for both materials with
off the controller and then carefully remove the
typical values published in material handbooks or texts
remainder of the specimen from the machine. Save the
(provide your reference source). Attempt to explain
fragments for sketching the mode of failure.
any observed differences.
17. Remove the plot from the X-Y plotter and turn off the
4. Discuss the general shape of the stress-strain curve for
plotter.
steel in the region beyond the yield point, especially
during the unload–reload cycles.
CALCULATIONS 5. Explain why the stress-strain plot for steel follows the
path it does after it has reached ultimate stress.
A graph with the appropriate titles and units should be 6. Using the plots for both materials; explain the
prepared, showing the stress-strain profiles for both the steel differences between linear, nonlinear, elastic and
and FRP specimens on the same axes. The LOAD vs. inelastic behaviour.
DEFORMATION plot obtained from the X-Y plotter and the 7. Explain the difference between brittle and ductile
recorded data from the caliper measurements should be used failure. In which of the tested materials were these
to prepare this graph. For steel, be sure to clearly label the failures observed?
proportional limit, yield point, ultimate strength, and point of 8. Discuss the fracture surfaces observed. How do they
rupture. For FRP, be sure to clearly label the point of relate to the ductility of the materials? (Sketches are
rupture. Use the data in this plot to produce a plot of stress helpful.)
versus strain for both materials.
Show all calculations and include original data sheets,
sketches, and notes in an appendix.
Using the formulae provided, determine the following USEFUL FORMULAE

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

P NOTATION
Stress: σ =
A
A cross-sectional area of specimen (mm2)
d
δ diameter of test specimen (mm)
Strain: ε= E elastic modulus (MPa)
Lo Efrp elastic modulus of FRP (MPa)
Es elastic modulus of steel (MPa)
Hooke's law: σ = Eε (elastic region only) Lo gauge length of extensometer (mm)
P axial load in (N)
t thickness of test specimen (mm)
P w width of test specimen (mm)
δ axial deformation of over gauge length (mm)
ε strain in specimen (mm/mm)
εfrp,ult percentage deformation at fracture for FRP
εs,f percentage deformation at fracture for steel
σ axial stress in specimen (MPa)
σfrp,ult ultimate tensile strength of FRP (MPa)
σp proportional limit (MPa)
σs,f stress at fracture of steel (MPa)
σs,ult ultimate tensile strength of steel (MPa)
σy yield stress (MPa)
L0
REFERENCES

1. American Society for Testing and Materials (ASTM),


A 1998. D3039 – Standard Test Method for Tensile
Properties of Fibre-Resin Composites
2. American Society for Testing and Materials (ASTM),
1998. E8M-03 – Standard Test Methods for Tension
Testing of Metallic Materials
3. American Society for Testing and Materials (ASTM),
1997b. A370-97a – Standard Test Methods and
Definitions for Mechanical Testing of Steel Products.
P

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ISIS Canada Educational Module No. 2: FRP Composites for Construction

Appendix B:
Suggested Student Assignment

Answer the following questions to the best of your ability. Additional references will likely need to be consulted. It is
suggested that students visit the library and consult texts on materials science, construction materials, and composite
materials.

Problem #1:

The developed world relies heavily on a complex and widespread system of infrastructure for economic and social health
and prosperity. However, much of our public and private infrastructure is now inadequate to meet the needs of current and
future generations. Briefly describe three factors which have led to the inadequacy of our infrastructure systems.

Problem #2:

List and describe the advantages of FRP materials for construction and repair applications in comparison with conventional
materials such as timber or steel.

Problem #3:

Compare and contrast the mechanical properties of FRP materials for construction and repair applications with those of
conventional materials such as timber or steel.

Problem #4:

Compare and contrast the environmental durability of FRP materials for construction and repair applications against that of
conventional materials such as timber or steel.

Problem #5:

List and briefly describe three applications of FRP materials in construction or structural repair applications. What
properties of FRP materials make them viable alternatives to conventional materials in these situations?

25

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