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International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
463

Compressive Strength of Uniformly Corroded Steel Angle
Members Retrofitted with CFRP
Aparna Ben
1
, Vikraman.R
2
, Cinitha.A
3
, P.K.Umesha
4
, Eapen Sakaria
5

1
P.G. Student,
5
HOD, Department of Civil Engineering, Saintgits College of Engineering, Kottayam, Kerala, India
2
Project Assistant,
3
Scientist,
4
Chief Scientist, CSIR-Structural Engineering Research Centre, Chennai
AbstractAs steel structures play an important role in civil
constructions, more attention is needed for repairing and
rehabilitation of such structures. One of the main problems
facing steel structures is corrosion which effectively reduces
total section area of steel members thus leading to stress
concentration in the corroded area. One potential solution to
these problems is retrofitting the corroded specimens with
FRP. In the present study ISA 100 x 100 x 6mm angle sections
of length 1m were corroded by galvanostatic method for the
unpainted portion. Accelerated corrosion tests were proposed
to carry out on angle specimens after conducting natural
corrosion on the specimen by immersing the specimens in
3.5% NaCl solution for four months. Meanwhile, the
specimens were subjected to alternate wetting and drying
process so that the specimens will be induced to chloride
induced corrosion. These corroded angles were then
retrofitted using FRP composites with epoxy adhesives. The
specimens were then subjected to compression testing in order
to understand the strength aspects. Numerical validation of
corroded and retrofitted specimens were carried out with
general purpose finite element software ABAQUS. Also the
theoretical values of design strength were calculated as per
Rankine Gordan formula. The theoretical design strength
values were then compared with the experimental values.
Keywords ABAQUS, Accelerated Corrosion, Carbon
fibre reinforced polymer (CFRP), Compressive strength,
Rankine Gordan formula , Retrofitting
I. INTRODUCTION
Steel structures may have to be retrofitted due to various
reasons. One of the major problems facing steel structures
is corrosion which effectively reduces the gross cross
sectional area of steel members thus leading to higher
stresses in the corroded area. Reduction of member
thickness also results in the reduction of member cross
section properties such as area and section modulus thus
affecting the buckling capacity of the members. In recent
years, a continuous increase has been experienced in using
CFRP for structural strengthening as well as repair works
due to its high specific stiffness, corrosion resistance, less
maintenance cost, weight and durability.

Residual capacity of the corroded members is evaluated
by classifying the section according to the level of
corrosion. But, at times it becomes very much difficult to
assess the residual capacity of an existing structure. A
damage model was proposed by Kayser and Nowak which
evaluated the reliability of a corroded steel girder bridge
over time. Another theory called interval probability
theory was proposed by Sarveswaran for assessing the
reliability of corrosion-damaged steel structures. Using this
theory, the remaining thickness of a severely corroded
element was represented by an interval number which
expressed the range over which there was uncertainty about
the thickness. Later, a methodology was developed by
Hathout for assessing the reliability of existing
transmission structures and lines in the presence of
structural deterioration. He derived the model for
probability of failure as a function of the cumulative
distribution of the standardized safety margin and the
damage state of the structure and then expressed the failure
probability in terms of the first four moments of the safety
margin probability distribution function. In the present
study steel angle sections were corroded by galvanostatic
method and retrofitted using FRP composites with epoxy
adhesives. The specimens were then subjected to
compression testing in order to understand the strength
aspects. Numerical validation of corroded and retrofitted
specimens were discussed.
II. METHODOLOGY
In the analytical part, the angle sections are theoretically
designed using Rankine Gordan formula. In the
experimental part, out of the three specimens, one
specimen was kept as the control specimen while the other
two were corroded. The specimens were initially subjected
to natural corrosion by immersing in 3.5% NaCl. The
corrosion was then accelerated using galvanostatic
corrosion method. Among the two corroded sections, one
was retrofitted with CFRP. Compression tests were then
carried out on the specimens to obtain the ultimate load
carrying capacity of the specimens. The adopted
methodology is shown in the figure below.

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
464

Fig 1: Flowchart representing the remaining strength prediction
III. ANALYTICAL STUDY
The sections under consideration come under the
category intermediate column since l/r ratio is between 40
and 150. For the case of intermediate columns, Rankine
Gordan Formula (RGF) has combined the two loads, that
is, the crushing load for short column and the Eulers
buckling load for long columns.
According to Rankine Gordans formula,
Crippling load P =


Where F
y
= yield stress
A = Area of the section
= a constant depending upon the grade of steel and
boundary conditions
For steel with F
y
= 315 N/mm
2
and with boundary
conditions both ends fixed, = 1/30000
l = length of the specimen
k = slenderness ratio =


I
vv
= minimum moment of inertia of the section
IV. EXPERIMENTAL PROGRAM
In total, three specimens were considered for the test, out
of which one was kept as the control specimen and the
other two were corroded. Initially, natural corrosion was
conducted in the specimens by immersing them in 3.5%
NaCl solution for about three months. Meanwhile, the
specimens were subjected to alternate wetting and drying
so that the specimens will be undergoing chloride induced
corrosion.

Later, the specimens were subjected to accelearated
corrosion methodology. Corrosion was allowed to occur
only for a height of about one-third from the bottom base
plate. Galvanostatic corrosion method was used to induce
corrosion where corrosion was induced artificially by
keeping the current constant during the entire corrosion
process by means of a galvanostat. In the present study,
structural member which was subjected to corrosion acted
as the anode and same steel was used as the cathode for
obtaining continuity. The electrolyte used was 3.5% of
sodium chloride, i.e. 35 gms of NaCl was required for 1
litre of water to get the desired salinity. By means of a
galvanostat, the anode and cathode in the cell were
connected to an external supply of constant current. The
anode was connected to the positive terminal of the supply
whereas the cathode was connected to the negative
terminal. When the external power supply was switched on,
the structural member acting as the anode got oxidized and
the same metal used as the cathode got reduced resulting in
a corroded section at the anode.
Fig 2: Initial condition of
specimens during natural
corrosion
Fig 3: Final condition of
specimens after natural
Corrosion

Fig 4:Schematic test setup for
doing accelerated corrosion


Fig 5: Typical test setup for
accelerated corrosion

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
465





Fig 6: 100 x 100 x 6mm (1m)
specimen after being subjected
to accelerated corrosion

After conducting accelerated corrosion, one of the
corroded specimen was retrofitted with carbon fibre
reinforced polymer (CFRP) using an adhesive. The basic
materials required for retrofitting with their typical
properties are as tabulated below:
i) Carbon fibre reinforced polymer (CFRP)
Carbon fibre is defined as a fibre containing at least 92%
carbon by weight. Carbon fibres generally have excellent
tensile properties, low densities, high thermal and chemical
stabilities in the absence of oxidizing agents, good thermal
and electrical conductivities, and excellent creep resistance.
ii) Adhesive
In the present study, the adhesive used for binding CFRP
to steel angle section was Araldite AW 106 resin/Hardener
HV 953U epoxy adhesive. It is a multi-purpose, viscous
material that is suitable for bonding a variety of materials
including metal, ceramic, and wood.
Table 1
Typical Properties Of Cfrp Used
Property Test Values
Modulus of Elasticity 240GPa
Tensile strength 3800N/mm
2

Density 1.7g/cm
3
Poissons ratio 0.22





Table 2
Typical Properties Of Adhesive
Property Test
Method
Resin Hardener

Colour/
Appearance
Visual Creamy,
viscous/
liquid
Amber
Liquid
Specific Gravity ASTM D-
792
1.17 0.92

Viscosity (cP) @
25C
ASTM D-
2393
50,000 35,000

Table 3
Typical Mixed Properties


Table 4
Recommended Cure Schedule
Property Test Values
Reaction Ratio (by weight) 100R/80H
Reaction Ratio(by volume) 100R/100H











Temperature

Handling
Strength

Minimum
Cure Time

Room temperature

30 minutes

7 days


Fig 7: Carbon Fibre used


International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
466

Fig 8: Resin and hardener
Initially, the corroded portion of the angle specimens to
be retrofitted was properly ground and cleaned with
acetone in order to have proper binding with CFRP. The
resin and the hardener was then mixed in 1:1 proportion by
volume and applied with a spatula to the pretreated
surfaces. Immediately after applying the resin-hardener mix
to the surface with a painting brush, CFRP was properly
pasted to the corroded portion of the specimen. After
pasting CFRP to the corroded surface, one more coat of the
resin-hardener mix was applied over the CFRP in order to
have proper binding and to protect the fibres from getting
damaged. The various steps involved in the retrofitting
technique are pictorially presented below:
Fig 9: Application of the
resin-hardener mix
Fig 10: Pasting of CFRP

Fig 11: Pasting of CFRP(different
view)

Fig 12: Application of additional
coat of resin hardener mix
After retrofitting the specimens, the specimens were
subjected to compression test. For performing compression
test, the specimens were initially placed between the two
heads in such a way that the centre of the flange plates of
the specimen coincides with the centre of bottom platform
and the top head of the compression testing machine. A
total of five LVDTs including two laser LVDTs were used
to measure deflection. Two numbers of strain gauges were
placed on the uncorroded specimens whereas in the
corroded specimen a total of four strain gauges were
pasted. At each load stage, deflection measurements were
recorded automatically using a data logger, which is
connected to a computer.

Fig 13: Experimental test set up


International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
467




Fig 14: Buckling modes of retrofitted, corroded and uncorroded
specimens 100 x 100 x 6mm(1m)
V. NUMERICAL MODELLING USING ABAQUS SOFTWARE
In the present study, angle sections MS 100 x 100 x
6mm with 1m length was considered. Flange plates of
diameter 200mm and thickness 16mm were fixed at both
the ends of the angular member. They were then subjected
to axial compressive forces. As outer surface area is more
susceptible to uniform corrosion, material from the outer
surface of the member was removed to simulate corrosion.
Hence, for modelling uniform corrosion using ABAQUS
software, the average thickness reduction was considered.
The analysis was done by taking into account the non linear
properties. The solid element used is element C3D8R
(Continuum, 3D, 8 node, Reduced Integration).It is an eight
noded linear hexahedral brick element and is used for
modelling because of the relatively small leg thickness of
the angular section compared to the other dimensions
which results in local buckling when subjected to axial
compressive load. A kinematic coupling restraint is defined
to constrain the motion of the top flange plate to the regions
below where all the translational and rotational degrees of
freedom are specified. Reference point is then established
in the top flange plate which passes through the centroid of
the section under consideration. Boundary conditions are
then given with all translation degrees of freedom at top
surface nodes except the vertical displacement as fixed and
all degrees of freedom restrained at bottom. Then axial
loading condition is simulated by applying load to the
reference point. The STATIC, RIKS approach is used to
solve nonlinear problems. In this method, load magnitude
is considered as an additional unknown and thus loads and
displacements are solved simultaneously. The results of
interest are the current displacements and the loads which
may be referred to a load proportionality factor.
The ultimate load is obtained by multiplying the load
given with the load proportionality factor.
Fig 15: Typical Finite
element model used
Fig 16: Discretised column
model




Fig 17: ABAQUS model simulating corrosion



VI. RESULTS AND DISCUSSIONS
The analytical, numerical and experimental studies were
carried out in order to assess the strength and behaviour of
corroded steel angle members. In this work, steel angle
sections were corroded for various weight loss percentages.
In order to study the behaviour of uniform corrosion on the
angle members, two corroded members were taken, out of
which one was retrofitted with CFRP. The ultimate strength
as well as deflection for various weight loss percentages
was studied. Five sets of studies were carried out mainly
focusing on the response of i) uncorroded specimen, ii)
specimen with 10% corrosion, iii)specimen with 20%
corrosion, iv)specimen with 30% corrosion, v)specimen
with 40% corrosion where corrosion is modelled for a
height of one-third from the bottom. They were modelled
using ABAQUS and the results were compared with the
theoretical values.The steel angle members considered for
the present study are intermediate columns with yield
strength of 315N/mm
2
. As the percentage of corrosion
increases, the ultimate capacity of the members decreases.


International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
468

This is because of thefact that as the specimens corrodes,
the dimension reduces which in turn reduces the moment of
inertia and thus the deflection increases. This is evident
from the theoretical values and the ABAQUS results.

Fig 18:Deflection contour and load-deflection graph
for uncorroded 100 x 100 x 6mm(1m) specimen

Fig 19:Deflection contour and load-deflection graph
for 10% corroded 100 x 100 x 6mm(1m) specimen


Fig 20: Deflection contour and load-deflection graph
for 15.11%corroded 100 x 100 x 6mm(1m) specimen



Fig 21:Deflection contour and load-deflection graph
for 20% corroded 100 x 100 x 6mm(1m) specimen



Fig 22:Deflection contour and load-deflection graph
for 30% corroded 100 x 100 x 6mm(1m) specimen



Fig 23:Deflection contour and load-deflection graph
for 40% corroded 100 x 100 x 6mm(1m) specimen




















International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
469

Table 5
Comparison of numerical and analytical values of
100 x 100 x 6mm (1m) corroded and uncorroded specimen
Sl.No Percentageof
corrosion (%)
Numerical
value(kN)
Analytical
value(kN)
1 0% 338.04 338.05
2 10% 305.18 320.29
3 15.11% 288.05 302.34
4 20% 271.92 285.80
5 30% 237.18 251.08
6 40% 204.15 216.13
A comparison between the numerical and analytical
values of the load carrying capacities of the uncorroded and
corroded specimens are tabulated as shown in Table 5.
From the analysis, it can be observed that the mode of
failure in corroded members is also buckling as in the case
of uncorroded members with the only difference that the
position of buckling is near the location of thickness
reduction and not at the center. This is because of higher
compressive stresses caused due to the reduction in the
cross sectional area in the bottom portion due to corrosion.
A comparison between analytical, numerical and
experimental values of the specimens is tabulated as shown
below.
Table 6
Experimental values of the 100 x 100 x 6mm(1m) uncorroded,
corroded and retrofitted specimens
Sl.No Remarks Percentage
of corrosion
(%)
Ultimate load
(kN)

1 Uncorroded 0 327.47
2 Corroded 15.11 203.50
3 Retrofitted 12.14 242.14
A bar chart showing the comparison of the buckling
loads of 100 x 100 x mm (1m) corroded specimen using
numerical and analytical methods is shown in Fig 24. From
the bar chart, it can be seen clearly that with the increase in
the percentage of corrosion, the strength decreases.
Also, the analytical value computed using Rankine
Gordan formula is found to be very closer to the numerical
value obtained from ABAQUS. Another bar chart showing
the ultimate loads of uncorroded, corroded and retrofitted
specimens are shown in Fig. 25.


Fig 25: Ultimate loads of uncorroded, corroded and retrofitted
specimens





Fig 24: Comparison of the buckling loads of
100 x 100 x mm(1m) corroded specimen using numerical and
analytical methods
VII. CONCLUSIONS
This work presents the compression test of 3 members,
out of which two are corroded at a level corresponding to
weight loss ranging from 12% to 16%.
Experimental
Uncorroded 327.47
Corroded 203.5
Retrofitted 242.14
0
50
100
150
200
250
300
350
L
O
A
D
k
N
)

0
50
100
150
200
250
300
350
400
0% 10% 20% 30% 40%
L
O
A
D
(
k
N
)

PERCENTAGE OF CORROSION(%)
Numerical
Analytical

International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
470

The capacity of corroded members lost between 20%
and 40% of their uncorroded capacity. The reduction in
capacity of many members was predicted using Rankine
Gordan formula, which gave a closer value compared to the
experimental value. The numerical, analytical and
experimental study confirms that there is a drastic
reduction in the load carrying capacity of the member for
40% thickness reduction compared to the uncorroded
specimens. From the compression test carried out on the
specimens, it was concluded that corrosion has a major
impact on the failure mode of the member. For the
uncorroded members, buckling was observed at mid height
whereas in the case of corroded members, the critical
region of failure shifted towards the location of minimum
thickness with the increase in the percentage of corrosion.
Out of the two corroded specimens in the set, one was
retrofitted with CFRP and subjected to compression testing.
From the experimental results, the ultimate load carrying
capacities of the uncorroded, corroded and retrofitted
specimens were obtained as 327.47kN, 203.5kN and
242.14kN respectively. It can thus be verified that the
retrofitted specimen showed an improvement in strength by
11.8% compared to the corroded specimen without being
retrofitted. Thus external bonding of CFRP has been clearly
established as a promising alternative strengthening
technique for steel structures.
Acknowledgement
This paper is published with the kind permission of the
Director, CSIR- Structural Engineering Research centre,
Chennai, India.



















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