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
Includesreinforced
reinforcedthermoset
thermosetand andthermoplastic
thermoplastic SOURCE:
resin
resin composites, reinforcementsand
composites, reinforcements and SOURCE: SPI
SPIComposites
CompositesInstitute
Institute
fillers .
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
Poissons 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 t r u c t u r a l D e s ig n W it h F R P C o m p o s it e s

STR U C TUR E
F R P R e p a ir

M a t r ix , F ib e r s L a m in a , L a m in a t e S t r u c t u r a l A n a ly s is
M ic r o m e c h a n ic s M a c r o m e c h a n ic s S t r e n g t h 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 e e r in g C o n s t a n t s

[Q ]1 ,2 [ F ib e r O r ie n t a t io n ] [S ] 1 ,2
M a t h e m a tic a l C o n s t a n t s M a t h e m a t ic a l C o n s t a n t s

[Q ] x ,y [S ] x ,y
T r a n s fo r m e d M a th . C o n s ta n ts T r a n s fo r m e d M a t h . C o n s t a n t s

[E ] x ,y [E ] x ,y
T r a n s fo r m e d E n g . C o n s ta n ts T r a n s fo r m e d E n g . C o n s t a n t s
 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 Manufacturers 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 Manufacturers 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
manufacturers
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