Strengthening of Concrete Structures. Shaun Loeding, P.E. Director Strengthening Division
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1 Strengthening of Concrete Structures Shaun Loeding, P.E. Director Strengthening Division
2 Overall Intent??? Design and implement structural solutions based on our experience and technologies. Shaun Loeding, P.E. Director - Strengthening Division
3 State of the Art Products Engineering Support Services Specialty Contracting Solutions that integrate products, engineering, and construction
4 Quick Facts Total Group Annual Revenues $400 million Offerings Products Engineering Construction Employees 2,500 + Products & Engineering $50 Million Regional Technology Centers Baltimore, Dallas, & Houston Construction Annual Revenues $350 Million ENR Ranking Largest Concrete Repair Contractor & 27 th Largest Specialty Contractor Projects 2,000-2,500 annually Typical Range $2,500 to $30 Million Labor Union & Open Shop Multiple Crafts 2,000-2,500 employees Markets Served North America & Middle East
5 Quick Facts Offices Corporate HQ: Hanover, MD North America Offices: Baltimore Baton Rouge Chicago Dallas Denver Detroit Ft. Lauderdale/Miami Hartford Kansas City Lake Charles Long Island Los Angeles New York Philadelphia Pittsburgh San Francisco Sarasota/West Florida Springfield International Offices: Abu Dhabi Dubai Qatar
6 Design-Build Construction Chimney & Stack Construction Silo & Tank Construction Pre-Engineered Structures Repair Services Concrete Repair Fireproofing Force Protection Pipe Rehabilitation Strengthening Corrosion & Cathodic Protection Refractory Linings Equipment & Pump Foundations Moisture Control & Waterproofing Building Envelope Historic Restoration Maintenance Services Industry Leading Specialty Contracting Services for New & Existing Structures
7 Repair Services Concrete Repair Fireproofing Force Protection Pipe Rehabilitation Strengthening Corrosion & Cathodic Protection Refractory Linings Equipment & Pump Foundations Moisture Control & Waterproofing Building Envelope Historic Restoration Maintenance Services Industry Leading Specialty Contracting Services
8 Products & Systems Strengthening Force Protection Pipe Repair & Upgrade Corrosion Control Moisture Control Concrete Restoration Equipment Foundations Post Tensioning Engineering Support Investigative Condition Assessment Engineering Product Customization Design Assist Specialty Full Design State of the Art Products Engineered Solutions
9 Agenda Introduction FRP (fiber reinforced polymers) - Most common uses for FRP - Design strategy (ACI 440.2R-08) - Installation techniques and QA/QC - FRP limitations & fire protection - Case Studies Conventional Techniques - Section Enlargement - External Post Tensioning New Strengthening Technologies (DUCON micro-reinforced concrete)
10 Strengthening = Upgrading Structural Capacity Why Strengthen?? Construction Defects Design Deficiencies New Loads Deterioration Seismic Upgrades Blast Upgrades
11 Direct Services Design-Development Conceptual designs and associated budgets Specification support Aid in overall engineering and strengthening analysis Site visits Solution/repair strategy Construction Final design calculations and shop drawings (PE stamped/sealed upon request) QA/QC and Safety Program project specific Trained, certified and experienced installers
12 FRP Composite what is it??? FRP = Fiber-Reinforced Polymer Composite = two or more materials that when combined create one composite behaving system (fiber + epoxy = composite, with new and distinct properties) OTHER NAMES USED: Carbon fiber Carbon FRP (CFRP) or Glass FRP (GFRP) Fiber reinforced composite (FRC) Fiber wrap Externally bonded FRP reinforcement
13 FRP Applications Strengthening Typically Carbon FRP (CFRP) Upgrade flexure and/or shear capacity of member CFRP = higher strength, higher material cost Restoration Typically Glass FRP (GFRP) Corrosion protection, spall protection GFRP = lower strength, lower material cost NOTE: CFRP and GFRP = lightweight, low profile, corrosive resistant, durable
14 FRP Applications
15 Rules of Thumb flexural strengthening with CFRP 12 CFRP strip 1 layer, 12 wide = (1)-#5 rebar (60ksi) Typical application uses CFRP strips of 8, 12 or 24 width Typical application uses 1 to 4 layers of CFRP CFRP may provide up to 40% additional capacity to an element Typical application requires 20%-25% additional capacity CFRP does not stiffen an element i.e. does not aid in reducing deflections or aid in satisfying service conditions of an element
16 FRP Design Principles & Engineering Considerations 440.2R-08
17 FRP Flexural Design Concepts b e c gf ' c c 1 c h d e s e f Strain in FRP? f s f f 1c M n As f s d 2 f A f f f h 1c 2
18 FRP Design Strain Limits Peeling de-bonding effect at ends Un-zipping de-bonding effect at flexural cracks C L
19 Stress (ksi) Design Stress/Strain Relationship Ultimate (Rupture) Flexural Design CFRP Steel GFRP Modulus, E: Steel 29,000ksi CFRP 12,000ksi GFRP 3,000ksi Strain
20 LOAD FRP Strengthening Limits ACI 440.2R Supplemental Reinforcement Member with FRP New Ultimate Loads: 1.2DL+1.6LL New 440.2R Loads: 1.1DL+0.75LL Original RC Member DEFLECTION Existing strength without FRP should be able to support demand from load case of 1.1DL+0.75LL (ACI 440.2R, Eq. 9-1)
21 LOAD FRP Strengthening Limits Fire Event Supplemental Reinforcement Member with FRP New Ultimate Loads: 1.2DL+1.6LL New Service Loads: 1.0DL+1.0LL (due to change) Original RC Member 2Hr Fire Reduced Capacity DEFLECTION Existing strength without FRP should be able to support typical service loads (1.0DL+1.0LL) after 2Hr Fire
22 Fire Protection Strategies Protect FRP for Applicable Burn Characteristics per ASTM E84 Intumescent Topcoat (Flame spread & smoke density) Intumescent (Burning- ASTM E84)
23 FRP Installation General Procedures Prepare substrate surface Provide surface primer/thickened epoxy on prepared substrate Saturate fabric sheet Install saturated fabric sheet Provide coating
24 Substrate Preparation for Bond Primer Open pores! 1.Abrasive blast 2.Dustless grinding & vacuum 3.Water blast & dry
25 Surface Preparation
26 Primer/Thickened Epoxy to Substrate
27 FRP Sheet Saturation
28 FRP Sheet Saturation
29 FRP Sheet Installation Prepared substrate Saturated fabric sheet Primed substrate
30 QC Acceptance Criteria Delamination Limits of delaminated FRP area to ensure adequate performance Tap Test Material Testing Tensile tests of laminate from field Bond Pull of tests to determine bond strength to concrete Minimum 200 psi
31 FRP Pull off Bond Test Requires Min. 200psi
32 Condo Building - multiple strengthening techniques due to design defects
33 Slab Strengthening FRP layout
34 Slab Upgrade FRP strips (positive bending)
35 Slab Strengthening (negative bending)
36 Wall removal required Slab Strengthening
37 Condo Building - multiple strengthening techniques due to design defects Shear collars Column enlargement
38 New Penetrations in Existing Slabs One direction Two direction
39 New Slab Penetrations
40 Existing Concrete Joists
41 Precast Double Tees - Stem cracks
42 Install FRP Shear U Wraps
43 Guggenheim Museum
44 Guggenheim Museum
45 Guggenheim Museum Chip Open crack
46 Guggenheim Museum Steel T-Section Rebar Discontinuous 5
47 Guggenheim Museum T-Bars
48 Guggenheim Museum and dry wall Prior to insulation
49 Guggenheim Museum Thru wall detail Bond Bond Grout
50 Guggenheim Museum Web Wall Bracket
51 MOMENT RESISTING FRAMES - Column failure Lack of plastic hinge confinement
52 Beam/Column shear strengthening (Performance of an RC Corner Beam-Column Joint by Engindeniz et al., 2007)
53 FRP Wrap Increase Axial Load Capacity
54 Column Repairs - Low Strength Concrete Enlarge FRP
55 Power Plant - Missing Seismic Steel
56 Power Plant - Missing Seismic Steel
57 Power Plant - Missing Seismic Steel
58 Power Plant - Missing Seismic Steel
59 FRP Near-Surface Mounted (NSM) Rod -
60 FRP Near-Surface Mounted (NSM) Rod - CFRP Bar Installation Finished Product
61 NSM Rod- Bridge Decks ( I-75, Florida)
62 NSM Rod- CMU Wall Application
63 I-75 Rouge Bridge, MI Column FRP Upgrade
64 Shear Upgrade with FRP
65 Completed Bridge Pier FRP Strengthening
66 FRP Strengthening NSM Anchorage of Shear Reinforcing FRP Sheet FRP rod Epoxy paste FRP reinforcement
67 Far Rockaway, Queens, NY Elevated A-Line
68 Far Rockaway, Queens, NY Elevated A-Line
69 Far Rockaway, Queens, NY Elevated A-Line
70 Far Rockaway, Queens, NY Elevated A-Line
71 Enlargement- Composite Behavior Existing New
72 Enlargement: Self-Consolidating Concrete 26-28
73 Section Enlargement
74 External Post Tensioning Upgrade NEW LOAD F Live end Dead end F Uplift at Deviator
75 External Post Tensioning Encased in Concrete PT Beam Damaged From Snow Load
76 External Post Tensioning Encased in Concrete
77 External Post Tensioning Encased in Concrete
78 DUCON Slurry-infiltrated Micro-Reinforced Ultra High Performance Concrete MicroMat Micro-Reinforcement DUCON Self Consolidating Slurry DUCON Ductile Concrete Tensile: ksi Compressive: ~ 20 ksi Compressive: ~ 22 ksi Tensile: ~ 3 ksi Shear: ~ 2 ksi
79 Bundled Wire Layers
80 Micro-reinforcement mesh Multiple layer mat (Plan View) Wire Size: 0.04 to 0.06 Wire Spacing: 0.3 to 1.0 Wire Strength: 60ksi or 80ksi meshes wire
81 Concrete Slurry Infiltration 15,000psi+ slurry
82 2 inches Micro-reinforced Concrete Slurry Diameter 0.9 inch MicroMat layers per inch
83 Bending Performance
84 Original Concept - Thin Load Bearing Elements
85 T-Beam Details 1 11'-0" 4" 16" 1 U-Shape Ducon (thickness varies) 10'-0" 10'-6" Beam BS2-D & BS5-D 36" 36" 4" 4" 12" 16 3/4" 12" 17 1/2" U-Shape Ducon (Thickness 1") 12" U-Shape Ducon (Thickness 1.75") 12" 14" 15 1/2" Beam BS2-D BS5-D
86 Surface Preparation - Roughen surface to ¼ amplitude (CSP-7) - No dowels required
87 Install Steel Mesh (specified layers)
88 Slurry Pumped into Forms (Material Flow Plexiglass Window) Slurry Pumping
89 Cured and Finished Product Test Beam
90 DUCON - Slab Overlay (structural and/or finish upgrades) Crack sealing Crack control Water-tight
91 Primary Applications - Review Precast Elements Thin and strong Column forms, walls Strengthening enlargement Beams and slabs (flexure, shear) Columns (axial, seismic) Surface Repair Crack sealing, crack control, water-tight Industrial flooring Blast Protection Energy dissipation Fragmentation and spall protection safety net
92 Spall and Breach SPALL RFC BREACH & SPALL RFC 18 inch 36 inch 18 inch
93 Stand Off & Perimeter Blast Threats (>20 standoff distance) 20 Slab, Column Or Wall 10 0 Primary Damage mode: Flexure Effects: Rotation Cracking Minimal Spalling Typical Blast Pressure Range: 4 psi - 10 psi 0ft 3ft 8ft 20ft STAND OFF CHARGE
94 Mid Range Blast Threat (>8 and < 20 ) Primary Damage mode: Flexure Secondary Damage mode: Shear Slab, Column Or Wall Typical Blast Pressure: 10 psi - 20 psi Effects: Some Spalling Small Projectiles No Breach MID RANGE CHARGE ft
95 Close Range Threat (>3 and < 8 ) 12 Slab, Column Or Wall Typical Blast Pressure: 6 0 Primary Damage mode: Shear Secondary Damage Mode: Flexure Significant Spalling Large Projectiles Possible Breach psi CLOSE RANGE CHARGE ft
96 Contact Detonation Blast Threat (< 3 ) 8 Slab, Column Or Wall Primary damage mode: Shear 4 Effects: Breach (certain) Shock wave penetrates Heavy Spalling Large projectiles CONTACT CHARGE Typical Blast Pressure: 200 psi 100K psi 0 0 3
97 DUCON Ultra High Performance Concrete Shear Strength Test
98 100 lb Close Range Detonation Testing Rear Side RFC
99 Contact Detonation Test Results Attacked Side No Breach Protected Side No Spall
100 Cast in Place Walls
101 DUCON INSITU SPALL LINERS (WALLS) 3
102 Cast in Place Walls
103 Cast in Place Walls
104 THE PARKLAWN BUILDING Department of Health and Human Services
105 The Parklawn Building 1200 Columns, 21 Column Sizes, 8 Different Conditions PHASE 2 PHASE 1 PHASE 3
106 Column Blast Shields Install wire mesh
107 Column Blast Shields Form and pump cement
108 Column Blast Shields Partial height column jacket Full height column jacket
109 DUCON - Precast Wall Panels
110 Blast Mitigation for Columns for Truck Sized Bomb at Curbside No FRP
111 Blast Mitigation for Columns with FRP No FRP
112 Blast Mitigation for Columns with FRP With FRP
113 Overall Intent??? Design and implement structural solutions based on our experience and technologies. Shaun Loeding, P.E. Director - Strengthening Division
114 Concluding remarks THANK YOU! Please visit and Technical design support Budgetary estimate support Repair and QA/QC specs Contracting services Technical Lunch-Box training seminars available: - Strengthening - Corrosion Protection - Concrete Repair - Building Envelope - Waterproofing - Force protection Current projects? Local contact: Shaun Loeding, P.E sloeding@structural.net
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