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
0.7%

Transportation
30.6%

Construction
20%
Other- 3.4%

Consumer
Products - 6%
Marine - 11.6%
Electrical/
Electronic - 10%
Corrosion-Resistant
Equipment - 12.4%
Includes
Includesreinforced
reinforcedthermoset
thermosetand
andthermoplastic
thermoplastic
resin
composites,
reinforcements
resin composites, reinforcementsand
and
fillers
.
fillers.

Appliance/Business
Equipment - 5.3%

SOURCE:
SOURCE: SPI
SPIComposites
CompositesInstitute
Institute

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
Type

Density Tensile Elong. ELong.

(kg/m3) Str.
(%) Mod. Term
(MPa)
(GPa) t ,(C)
Polyester
1.2
50-65
2-3
3
120
Vinyl
Ester

1.15

70-80

4-6

3.5

140

Epoxy

1.1-1.4

50-90

2-8

120200

Phenolic

1.2

40-50

1-2

120150

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

Alum

2.76

E-Glass

1.99

S-Glass

1.99

Carbon

1.59

Aramid

1.38
0

10

FIBER PROPERTIES
TENSILE STRENGTH
Alum

20

Steel

60

S-Glass

625

Carbon

530

Aramid

525

E-Glass

500
0

200

400

x103 psi

600

800

FIBER PROPERTIES
STRAIN TO FAILURE
Alum

0.2

Steel

0.16

S-Glass

E-Glass

4.8

Aramid

2.8

Carbon

1.4
0

(%)

FIBER PROPERTIES
TENSILE MODULUS
Alum

10

Steel

29

Carbon

33.5

Aramid

19

S-Glass

12.6

E-Glass

10.5
0

10

106 psi

20

30

40

FIBER PROPERTIES
CTE - Longitudinal
14

12.6

12
10

x10 / C
-6 0

6.5
5

6
2.9

4
2

0.5

0
-2

Aramid
-2

Carbon

S-Glass

E-Glass

Steel

Alum

FIBER PROPERTIES
THERMAL CONDUCTIVITY
1500

1600
1400
1200
1000

x10-6/0C

800
600
400
200
0

1.5
FRP

115
Steel

BTU-in/hr-ft2 - 0F

7.5
Alum

Concrete

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
Type

Density
(kg/m3)

Tensile
Strength
(GPa)
1.72-3.45

Elong.
(%)

2.54

EModulus
(GPa)
72.5

E-Glass
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
(HS)
Carbon
(HM)
Carbon
(UHM)

1.80

227

2.80-5.10

1.1

1.80-1.86

370

1.80

0.5

1.86-2.10

350-520

1.00-1.75

0.2

2.5

ADVANTAGES AND
DISADVANTAGES OF
REINFORCING FIBERS
Fiber Type

Advantages

E-Glass, S-Glass High Strength,

Low Cost
Aramid
High Strength,
Low Density
HS Carbon
UHM Carbon

High Strength
and Stiffness
Very High
Stiffness

Disadvantages
Low Stiffness,
Fatigue
Low Compr.
Str., High
Moisture
Absorption
High Cost
Low Strength,
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/
Epoxy
Fiber Volume
0.55
Longitudinal Modulus GPa 39
Transverse .Modulus,
8.6
GPa
Shear Modulus,
3.8
GPa
Poissons
0.28
Ratio
Long.Tensile Strength
1080
MPa
Compressive Strength,
620
MPa

S-Glass/
Epoxy
0.50
43
8.9

Aramid/ Carbon/
Epoxy Epoxy
0.60
0.63
87
142
5.5
10.3

4.5

2.2

7.2

0.27

0.34

0.27

1280

1280

2280

690

335

1440

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
Material

AXIAL
EFFICIENCY
Rank
E/

FLEXURAL
EFFICIENCY
Rank
E1/2/

Carbon/Epoxy

113.1

8.4

Kevlar/Epoxy

52.1

6.0

E-Glass/Epoxy

21.4

3.5

Mild Steel

25.6

1.8

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
M ic r o m e c h a n ic s

L a m in a , L a m in a t e
M a c r o m e c h a n ic s

S t r u c t u r a l A n a ly s is
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
M a t h e m a tic a l C o n s t a n t s

[ F ib e r O r ie n t a t io n ]

[S ] 1 ,2
M a t h e m a t ic a l C o n s t a n t s

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

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

[E ] x ,y
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:
PART GEOMETRY:
PRODUCTION VOLUME:
CYCLE TIME:
SURFACE FINISH:
TOOLING COST:
EQUIPMENT COST:

Unlimited
Simple - Complex
Low - Med
Slow
Good - Excellent
Low
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 YIELDNOT 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 BEAMSFAILURE 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 FRPRetrofitted 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 FRPRetrofitted 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 BeamWet 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