FIBER REINFORCED POLYMER

(FRP) COMPOSITES REBAR

John P. Busel
Director Composites Growth Initiative
Director,
American Composites Manufacturers Association
July 17, 2012

FL-DOT, Tampa
Outline

About ACMA
Introduction
FRP Materials
FRP Bars
S d d & SSpecifications
Standards ifi i
Applications
Summary
 About ACMA
3

Formed in 1979
Worlds largest composites trade association representing:

Material Suppliers &

Manufacturers Distributors

Composites Industry
3000+ Companies
280,000+ employees
North America

Industry Academia
Consultants
ACMA Industryy Council

Mission - Promote the use and growth of FRP

reinforcement (rebar, tendons & grids) in concrete and
masonry applications through development of quality
procedures, industry specifications, performance
standards, and field application guidelines.
FRP-RMC Manufacturers

BP Composites (TUFF
(TUFF-Bar)
Bar)
Composite Rebar Technologies, Inc.
Hughes Brothers
Brothers, Inc
Inc. (AslanFRP)
Marshall Composite Technologies, Inc. (C-Bar)
P l ll Inc.
Pultrall, I (V-Rod)
(V R d)
Introduction

The Problem - Corrosion

Corrosion and deterioration of steel reinforced concrete
Mitigation techniques - High costs to rehabilitate and
remediate structures
Safety - Construction zones and detours

The Solution FRP Rebars

Non corrosive concrete reinforcement
Increase service life (durability)

Hundreds of applications in service in North America

Traditional Approach to Corrosion
P bl
Problems
Reduce, Eliminate, or Negate the Current Flow of the
Electrochemical Corrosion Cell Inherent With Steel
Reinforced Concrete
Admixtures
Increase Concrete Cover
Efforts to reduce permeability & mitigate cracking - HPC
Alter Concrete Mix
Membranes & Overlays
Epoxy
p y coated steel
Cathodic protection
Sacrificial anodes
FRP Materials
M i l
Wh are composites
Why i different?
diff ?
FRP Materials C tit
Constituents
t

What is FRP?
Fibers Matrix
Provide strength and Protects and transfers
stiffness load between fibers
Carbon glass,
Carbon, glass aramid Polyester,
y , Epoxy,
p y,
Vinyl Ester, Urethane

FiberCompositesMatrix
Creates a material with attributes superior to either component alone!
fibers and matrix both play critical roles in the composites material...
Factors Affecting Material
Ch
Characteristics
t i ti
Type of fiber
Fiber volume
Type of resin
Fiber orientation
Q li controll procedures
Quality d d
during
i manufacturing
f i
Rate of curing
Void content
Service temperature
What is different?

FRP is Anisotropic
High strength in the direction of the fibers
This anisotropic behavior affects the shear strength,
dowel action, and bond performance
FRP does not exhibit yyielding:
g the material is linear
elastic until failure
Design
should account for lack of ductility
Member does have substantial deformability
Composites
p Features

Impervious
p to chloride ion and chemical attack
Tensile strength is greater that steel
the weight of steel
Transparent to magnetic fields and radar frequencies
Electrically non-conductive
Thermally non-conductive
Where should FRP rebar be used?

Any concrete member susceptible to corrosion by

chloride ions or chemicals
Any concrete member requiring non-ferrous
reinforcement due to Electro-magnetic considerations
As an alternative to epoxy, galvanized, or stainless
steel
t l rebars
b
Where machinery will consume the reinforced
member ie.ie Mining and tunneling
Applications requiring Thermal non-conductivity
 Tensile Stress-Strain Characteristics
400

FRP Composite Types Linear elastic

CFRP behavior to
AFRP
300 GFRP failure
2000 MPa
e Stress (ksi)

No yielding
200
Higher Ultimate
Tensile

Strength
1000 MPa
100 Lower Strain at
Failure
Typical Steel Rebar
0
0 1 2 3

Tensile Strain (%)

FRP Properties
p

Steel GFRP CFRP AFRP

Yield Stress
ksi 40 - 75 N/A N/A N/A
(MPa) (276 - 517)
Tensile Strength
ksi 70 - 100 70 - 230 87 - 535 250 - 368
(MPa) (483 - 690) (483 - 1600) (600 - 3690) (1720 - 2540)
Elastic Modulus
X 103 ksi 29 5.1 - 7.4 15.9 - 84 6.0 - 18.2
(MPa) (200) (35 - 51) (120 - 580) (41 - 125)
Yield Strain % .14 - .25 N/A N/A N/A

Source: ACI 440.1R-06

Coefficient of Thermal Expansion
p

-6 o
CTE (10 / F)
Material Longitudinal Direction Transverse
Concrete 4~6 4~6
Steel 6.5 6.5
GFRP 3.5 ~ 5.6 12
CFRP -4 ~ 0 41 - 58
AFRP - 3.3 ~ - 1.1 33 - 44

Values of CTE differ between FRP materials and concrete.

Effect of High
g Temperatures
p

Resins will soften due to excessive heat

The tensile, compressive, and shear
properties of the resin diminish when
temperatures approachh the h Gl
Glass
Transition Temperature, Tg
Tg values are approximately 250oF
(120oC) for vinylester resins which are
typically used with GFRP rebars
Tg lowers as a result of moisture
absorption
FRP bars
b
L k are deceiving
Looks d i i
Pultrusion
u us o Process
ocess M
Manufacturing
f t i Processes
P

Heated Die Cured

Profile
Resin

Most products are manufactured with this process

FRP Bar Types
yp

Materials
Glass/ vinylester

Carbon/ vinylester

Forms
Solid
FRP bar types
yp

Surface
Ribbed (a) a)

Sand Coated (b)

Wrapped and Sand b)
Coated (c)
D f
Deformedd
c)
Helical
Innovation hollow bar - coming
g soon

Courtesy of Composite Rebar Technologies, Inc.

Bar Sizes
Bar Size Nominal Diameter
Imperial Metric Imperial Metric
Inches mm inches mm
#2 6 0 25
0.25 6 35
6.35
#3 10 0.375 9.53
#4 13 0.4 12.7
#5 16 0.625 15.88
#6 19 0.75 19.05
#7 22 0.875 22.23
#8 25 1 25.4
#9 29 1.125 28.65
#10 32 1.25 31.75
Strength
g and Modulus Grades

Strength grade is based on ultimate tensile strength

of the bar.
Lowest grade is 60 ksi
Strength is provided on 10 ksi increments
Grade F 60
f fu* >60 KSI
Grade F 300 >300 KSI

Modulus
M d l grade d corresponds
d to minimum
i i modulus
d l off
the selected bar.
S d d & Specifications
Standards S ifi i
T
Translating
l i researchh iinto iindustry
d standards
d d
ACI rebar design
g guideline
g

Design principles well

established through extensive
research
Guideline documents published
in North America, Europe,
Japan
p
Non-mandatory language
ACI rebar,, materials spec
p

ACI 440.6-08,
440 6 08 mandatory
language (standard document)
Provisions governing testing
and evaluation for certification
and QC/QA
Describes
esc bes permitted
pe ed constituent
co s ue
materials, limits on constituent
volumes, and minimum
performance requirements
ACI rebar,, construction spec
p

ACI 440.5-08, mandatory

language (standard
document))
GFRP bar preparation,
placement (including cover
requirements reinforcement
requirements,
supports), repair, and field
cutting
AASHTO design
g guide
g
New AASHTO LRFD design
guide specifications published
11/2009

Bridge decks and traffic

railings, glass FRP (GFRP) bars

Specific properties of GFRP

reinforcement, design
algorithms
l i h and d resistance
i
factors, detailing, material
and construction specifications
ACI Test methods
Rebar Test Methods

ACI 440.3R
440.3R-0404 (12) test methods for FRP rebars
ASTM D30 (Composite Materials) and D30.05
(Structural Test Methods) committees, now D30.10
Test Method ASTM Standard
B.1. Bar Cross-Section D7205-06 (R11)
( )
B.2. Bar Tension D7205-06 (R11)
B.4. Bar Transverse Shear D7617-11
B.6.
6 Bar Alkaline Tension WK27200
2 200
B.8. Bar Creep Rupture D7337-07
pp A. Bar Anchors
App. D7205-06 ((R11))
Canada - Highway
g y Bridge
g Design
g Code

Technology
gy transitioned from
government-subsidized research
projects to actual
commercialization
Experience gained on viability
of construction management
practices where FRP
reinforcement is adopted
through
g traditional bid letting
g
processes and competitive
bidding from multiple FRP bar
suppliers
Canadian Standards

CSA S807 09
Qualification and
QA criteria
Quality Assurance - Verification and
t
traceability
bilit off bar
b properties
ti
Durabilityy

ISIS Canada reports

on Durability
performance of GFRP
bars in Bridge Decks in
Service for 8-10 years
M lti l reports
Multiple t ffrom
several institutions
NO Degradation of
GFRP bbars ffound
d!
..a closer look
A li i
Applications
M
Many iinstallations
ll i and
d growing
i
TEA-21

FY 98-03
98 03 - IBRC Program
P
124 FRP Projects - $87M funded
44 decks
14 rebar
33 repair
p
6 tendons
27 others (i.e. FRP glulam)
19 states with FRP decks
Future funding - uncertain
Installations Todayy

In the U.S.
>190 installations that use FRP composites
>50 installations where FRP bars are used in bridge
decks
15 states (CO, FL, IA, IN, KY, MO, NC, NY, OH, OR, TX,
UT VT,
UT, VT WI
WI, WV) use FRP bars in bridge decks
In Canada,
>195
95 installations that use FRP composites
p
190 installations use FRP bars in bridge decks,
parapets, barriers, sidewalks
Applications
pp

Cast in Place
Precast
Top mat
Top and bottom mat
D k parapets, sidewalks
Decks, id lk
Other applications: tunneling (soft eye, seawalls,
MRI rooms, light
li h railil foundations,
f d i railway
il girders,
id
culverts, and many more.
 FRP Rebar for Decks &
Approach Slabs A li ti
Applications

Sierrita de la Taylor Bridge Pierce Street Wotton,

Cruz Creek Manitoba Bridge,
B id Quebec
Q b
Bridge, Lima OH Canada
Canada
Amarillo, TX USA
2000 USA
2000,
Morristown Bridge
g Vermont 2002

Concrete cast-in-place Bridge opened to traffic

Ma 2002
May J l 2002
July

Courtesy of Pultrall, Inc.

 3. Impact
Emma Park Bridge, Pleasant Grove,
Ut h DOT
Utah DOT, 2009

(Courrtesy of Hughees Brothers, Innc.)

Emma Park Bridge
g

Full Depth Precast top & bottom mat

Cost premium in 2009 to use GFRP over Epoxy bar
14% greater deck cost due in large part to additional
girders
On a 1:1 basis, GFRP bars equal in unit price to epoxy
steell
53rd Ave Bridge
g Bettendorf,, IA 2001

Courtesy of
Hughes Bros.
 Floodway Bridge, Manitoba, Canada
(2005)
2 Bridges
g 8 spans
p each
2 Lanes Each Bridge
142 feet typical span
1136 feet
f t ttotal
t l llength
th (1/5 mile)
il )
50 foot Wide
9 inch thick Deck Slab
8 feet Girder Spacing
 Floodwayy Bridge,
g , Manitoba,, Canada

LLargestt St
Steell FFree D
Deckk Project
P j t
Largest FRP reinforced bridge in the world
8 Truckloads off GFRP Rebar
150 Tons of GFRP = 1.2 million lbs of steel rebar
(30 truckloads)

Primarily #8 and #3 Longitudinal

#6 Transverse
3200 CY concrete (6400 tons)
 Floodwayy Bridge,
g , Manitoba,, Canada

Courtesy of
H h Bros.
Hughes B
 OReillyy Bridge
g - Canada
New anchor head used Courtesy of Pultrall, Inc.
Noden Causewayy

Prestressed/precast deck Courtesyy of Pultrall,, Inc.

Noden Causewayy

Courtesy of Pultrall,
Pultrall Inc.
Inc
Noden Causewayy

Courtesy of Pultrall, Inc.

 I-75- Tampa ~ Deck Replacement
NSM Stitching

Courtesy of
H h Bros.
Hughes B
 Courtesy of Hughes Bros.
New Precast deck panels , NSM stitched at night leaving bridge open to
traffic during high volume use in daytime.
Structural Strengthening Bridge
Cantilever Old Florida Keys Bridge

Cast in place repair with

GFRP & CFRP bars
 Prefabricated FRP stay-in-place
reinforcement panels
Large-size 24 x 8, double-layer stay-in-place (SIP) reinforcing
panels pre-assembled using off-the-shelf
ff f pultruded GFRP
G components
1.5 I-bars 1/8 thick epoxy
(4 o.c. perpendicular to traffic) bonded form plate

Three part cross rods

Three-part Vertical connectors
(4 o.c. parallel to traffic)
 Deck construction

Day 1: SIP panels setting and anchoring

Heavy Rail Miami MetroRail MIA
2 4 Miles of elevated rail
2.4
Rail Plinths 100% reinforced with GFRP Bars
Seawalls

C
Courtesy off Marshall
M h ll C Composite Tehnologies
h l
 Su a y
Summary
Co p e e se
Complete set oof guides,
gu des, test
es methods
e ods and
a d standards
s a da ds are
ae
available for GFRP bars
Many bridges built with GFRP bars and performing well
Non-proprietary solution, traditional supply chain
acquisition & installation in place
Extended service life of GFRP reinforced decks is expected
Many practices adopted for corrosion protection are not
necessary withi h FRP bbars
Holistic view of bridge deck construction makes FRP bars
the best value proposition
Composites
p Conference

www.compositesshow.org
COMPOSITES 2013
Orange County Convention Center, Orlando, FL
January 29-31, 2013
Over 4,000 attendees
Technical papers and educational sessions on
many topics
t i iincluding
l di iinfrastructure
f t t and
d
construction
Expo with suppliers and manufacturers
LRFD Pultruded Composites
p

Pre-Standard released 2010

Ch. 1 General Provisions
Ch. 2 Design Requirements
Ch. 3 Tension Members
Ch. 4 Compression Members
Ch.
Ch 5 Flexural
Fl l and
d Sh
Shear
Members
Ch. 6 Combined Forces &
Torsion
Ch. 7 Plates and Built-Up
M b
Members
Ch. 8 Bolted Connections
Thank You

John PP. Busel

Director, Composites Growth Initiative
A
American
i Composites
C it Manufacturers
M f t Association
A i ti
(ACMA)
P 914
P: 914-961-8007
961 8007
E: [email protected]