Glass Fiber Reinforced Polymer(GFRP) Rebar For Sustainable Infrastructure

Transcription

1 Glass Fiber Reinforced Polymer(GFRP) Rebar For Sustainable Infrastructure Borna Hajimiragha M.Eng, President and CEO at B&B FRP Manufacturing inc. March 2016

2 Videos 1. Composite Rebar 2. GFRP reinforced Beam (OR) 3. GFRP reinforced Beam 2

3 OUTLINE 1. What justifies the use of MST-BAR in today's infrastructures? 2. How MST-BAR is manufactured 3. Main advantages of MST-BAR 4. Codes, Designs & Standards 5. Mechanical & physical properties and durability of MST-BAR 6. Cost Analysis 7. Structural behavior of Reinforced Concrete(RC) with different types of rebar 3

4 WHY MST-BAR FOR TODAY INFRASTRUCTURES Corrosion on bridge barrier walls Corrosion on bridge decks & Utility poles 4

5 WHY CORROSION IS A PROBLEM? Governments & Taxpayers can no longer afford to pay concurrently for replacing, maintenance and expansion of infrastructure Corrosion is draining the economy silently Safety of infrastructures Steel is an old material, it s great but often does not fit some applications! IS IT THEN JUSTIFIABLE TO BUILD AIRPLANES, SPACE SHUTTLES OR GAS- STATION TANKS USING STEEL?!!! 5

6 MST-BAR Advantages Over Steel Rebar CORROSION RESISTANCE - 100% resistance to any & all harsh environmental factors BONDING STRENGTH - Much greater Bonding Strength to Concrete Ease of Cutting - For TBM Application - Soft Eye Fire rated- capacity to stand for more than 2 hours in direct fire with minimum concrete cover Strength - 2 times stronger than steel with tensile strength of 1000MPa Fatigue Strength - 20 times higher resistance under cyclic loading Weight - 4 x lighter than steel (2100 Kg/m3 vs Kg/m3) Economical Curing - Concrete can be cured with sea water instead of clean water; economical & recyclable Conductivity - Electromagnetic non-conductive; for MRI Applications & other uses Thermal non-conductivity - Makes it suitable for use in hot and cold environments Detection by GPR - Easily detected by GPR Thermal expansion - Very low thermal expansion factor results in added compatibility with concrete 6

7 Codes, Designs & Standards Substitution - Direct substitution of MST-BAR rebar with steel rebar may not be possible in certain cases Economy & Savings - Lower modulus of elasticity and shear strength have a direct impact on the number of required reinforcing bars Shear Strength MST-BAR requires different factors and formula as per CSA and ACI codes to be used as a shear reinforcement See the following three slides for further information

8 MST-BAR - Mega Strength Bar Part 1: Mechanical & Physical Properties of Straight GFRP Tensile Strength (MPa) 1000 Loss of Tensile Strength at -40C 0% Drop Ultimate strain % 1.5-2% Transverse Shear Strength (MPa) 220 Elastic Modules (MPa) >60,000 Bond Strength to Concrete (MPa) >20 CURE RATIO % 100 Glass Transition Temperature, C 125 Density(Kg/m 3 ) 2100 STEEL 450 It gets brittle 15% ,000 to 200,000 >12 N/A N/A 7800 Other GFRP Bars Not tested 1-1.5% 150 MPa 40,000 to 60,000 >12 Poor cure ratio

9 Canadian Standard Association (CSA) CAN/CSA-S6-06 (2006) Fibre Reinforced Structures, Canadian Highway Bridge Design Code Canadian Standards Association, pg CAN/CSA-S (R2007) Design and Construction of Building Components with Fibre- Reinforced Polymers Canadian Standards Association The Structural Innovation & Monitoring Technologies Resource Centre (SIMTReC): Manual No. 3 (Version 2) Reinforcing Concrete Structures with Fibre Reinforced Polymers (FRPs), Dr. Sami Rizkalla, Dr. Aftab Mufti Manual No. 4 Strengthening Reinforced Concrete Structures with Externally-Bonded Fibre Reinforced Polymers (FRPs), Dr. Kenneth Neale Manual No. 5 Prestressing Concrete Structures with FRPs Dr. Ivan Campbell USA ACI 440.1R-06 (2006) Report on Fiber Reinforced Poly. (FRP) Reinforcement for Concrete Structures, ACI Committee 440, American Concrete Institute ACI 440R-07 (2007) Report on Fiber-Reinforced Polymer (FRP) Reinforcement for Concrete Structures ACI Committee 440, American Concrete Institute ACI (2008) Specification for Construction with Fiber-Reinforced Polymer Reinforcing Bar ACI Committee 440, American Concrete Institute ACI (2008) Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials for Concrete Reinforcement, ACI Committee 440, American Concrete Institute AASHTO GFRP-1 (2009) AASHTO LRFD Bridge Design Guide Specifications for GFRP- Reinforced Concrete Bridge Decks and Traffic Railings, American Association of State Highway and Transportation Officials

10 Standard & Approvals American Concrete Institution (ACI-440.3) Canadian Standard Association (CSA-S807) ISO 9001:2008 Quality Control BSI-British Standard Institution

11 Stress-Strain Curves Stress Vs Strain Chart: Steel s maximum stress level is 500MPa and GFRP is above 1000MPa for the same diameter. That is twice the load capacity of steel. Actual Test Curve of MST-BAR for 16mm diameter bar Comparison of MST-BAR with Steel and Carbon bar

12 Crack Width (mm) Fatigue Comparison GFRP/CFRP/STEEL Comparison of GFRP, CFRP and STEEL Reinforced Slabs Fatigue under 60 t Load Fatigue under 60 t Load STEEL GFRP CFRP 100 1,000 10, ,000 1,000,000 No. of Cycles (Nos.) Punching Shear Failure Mode STEEL CFRP GFRP Cycles to 60 t 23,162 Cycles 198,863 Cycles 420,684 Cycles

13 MST-BAR : Completed Test Part A. Physical Properties All The Tests are Completed in University Of Sherbrooke Under Supervision of Dr. Brahim Benmokrane Prof. Dr. Brahim Benmokrane P. Eng., FRSC, FACI, FCSCE, FIIFC, FEIC, FCAE Professor of Civil Engineering Fellow of the Royal Society of Canada (Academy of Science) Canada Research Chair in Advanced Composite Materials for Civil Structures NSERC Research Chair in FRP Reinforcement for Concrete Infrastructure Director of the Quebec-FRQNT Research Center on Concrete Infrastructure ( CRIB) Director of the University of Sherbrooke Research Center on FRP Composite Materials for Structures (CRUSMaC)

14 MST-BAR : Completed Test Part B. Mechanical Properties Tensile properties at Ambient Temperature Tensile Properties at -40 C Durability test in Alkali Environment at 60 C, PH level 13 for 90 days Bond Strength (Pullout) Transverse Shear Strength Creep Rupture and Strength Bent Bar Tests

15 MST-BAR : Typical Preparation for Mechanical Testing Typical preparation of MST-BAR for tensile test. In order to achieve the exact load capacity of MST-BAR and avoid any premature failure of the bar due to compression at the clamp, the two ends of the bar are anchored to a heavy duty pipe with a special grout to add grip on Universal Tensile Test machine grips.

16 MST-BAR : Typical Preparation for Mechanical Testing Typical package of MST-BAR for CSA & ACI tests. All MST-BAR were shipped to University of Sherbrooke to be tested.

17 MST-BAR : Typical Preparation for Mechanical Testing Preparation of MST-BAR for Alkali resistance under load. The test was carried out in an environmental chamber with a 60C temperature. The white tubes are filled with a high alkali mixture with a ph level of 13, under 3000 micro strains load for 90 days.

18 Typical Preparation for Creep Test Preparation of MST-BAR for Creep and Creep Rupture tests. The bars were placed under a constant load for a period of ONE full year and the strain in the material was measured in order to determine the maximum load under which the bar might remain unaffected for 113 years.

19 Typical Failure of MST-BAR in Tensile Test Figure 1: LVDT & Test Setup Figure 2: Typical Failure of MST-BAR Tensile Strength >1000MPa

20 MST-BAR - Tensile Properties of 20mm Bar at -40 C Temperature Test Setup in -40C, Failure of bar beyond the 1000MPa NO REDUCTION IN STRENGTH

21 MST-BAR - Bar 15mm - Durability test at 60 C, ph Level of 13 for 90 Days(2160h) After the bars have been Removed from alkali bath, Sodium, Calcium and Magnesium sediments are observed on the surface of the bars.

22 MST-BAR - Bar 15mm - Durability test at 60 C, ph Level of 13 for 90 Days MST-BAR in Alkali resistance under load for 2160h, at 60C temperature With a ph level of 13: IT WILL RETAIN OVER 90% OF ITS ORIGINAL STRENGTH.

23 Transverse Shear Strength Test Shear Test Setup TRANSVERSE SHEAR STRENGRTH BEYOND 220MPa IS MAINTAINED.

24 MST-BAR - Bond Strength MTO & CSA Requirements are only 8MPa ALL MST-BAR BOND STRENGTHS WERE FOUND TO BE BEYOND 20MPa

25 Bond Strength/Pull-OUT Test Typical Pull-out test/bond Strength with concrete, In Excess of 100 tests were completed in order to determine the pull-out capacity of the MST-BAR.

26 MST-BAR - Bond Strength Graph below shows the slippage of the bar in concrete. The average bond strength for MST-BAR is above 20MPa with less than half mm slippage.

27 MST-BAR 10MM Under Creep Test Creep test set-up to apply constant load on the bars.

28 Creep Rupture & Creep in Bar #3 (10mm) Chart below clearly illustrate and shows that MST-BAR can continuously be in service for Log6(h) or 113 years, when it is subjected to 49% of it s capacity(500mpa).

29 MANY SUCCESSFUL PROJECTS COMPLETED Parking Garages Commercial Applications Bridges Water Treatment Plants Chemical Plants

30 Case 1: STEEL Vs. GFRP Fibre reinforced polymer composite bars for the structural concrete slabs of a Public Works and Government Services Canada parking garage Brahim Benmokrane, Ehab El-Salakawy, Zoubir Cherrak, and Allan Wiseman NRC CANADA 2004

31 Fibre reinforced polymer composite bars for the structural concrete slabs of a Public Works and Government Services Canada parking garage Brahim Benmokrane, Ehab El-Salakawy, Zoubir Cherrak, and Allan Wiseman NRC CANADA 2004

32 Result Summary Fibre reinforced polymer composite bars for the structural concrete slabs of a Public Works and Government Services Canada parking garage Brahim Benmokrane, Ehab El-Salakawy, Zoubir Cherrak, and Allan Wiseman NRC CANADA 2004

33 Crack Details Fibre reinforced polymer composite bars for the structural concrete slabs of a Public Works and Government Services Canada parking garage Brahim Benmokrane, Ehab El-Salakawy, Zoubir Cherrak, and Allan Wiseman NRC CANADA 2004

34 Crack Pattern at Failure Fibre reinforced polymer composite bars for the structural concrete slabs of a Public Works and Government Services Canada parking garage Brahim Benmokrane, Ehab El-Salakawy, Zoubir Cherrak, and Allan Wiseman NRC CANADA 2004

35 COST SAVINGS OF MST-BAR TRANSPORTATION COSTS - 4 times lower due to its 73% lighter weight Minimum required concrete cover - 38mm for bars #2-5 and 50mm for bars #6-8, the regular steel bar concrete requires 65mm Increased installer performance & less fatigue due to lighter weight - faster/cheaper installation MST-BAR price with its proven higher performance will not add any extra cost to the project how ever it will result in saving. No water proofing membrane - a unique cost-saving feature NEVER Epoxy-coat/paint/re-patch the concrete or replace the rusted bars - MST-BAR does not required any maintenance CONCLUSION: MST-BAR with its proven higher performance not only will not add additional costs to the project; it will certainly result in major savings

36 Cost Study: BLACK STEEL Chloride ions, moisture and salts will penetrate through the membrane and begin corroding its top reinforcement CONCLUSION: 25 years after the road construction, its asphalt surface will have to be rehabilitated, the membrane would require replacement and the upper reinforcement would corrode needing to be replaced. Considering the life span of MST-BAR at well over 100 years, the savings that it brings to any and all construction projects is undoubtedly substantial

37 STUDY ON COST : DIFFERENT REINFORCEMENET 1,400,000 1,200,000 1,000, , , , , YEARS 25 YEARS 50 YEARS 75 YEARS 100 YEARS 150 YEARS MST-BAR Stainless-Steel Epoxy-coated Black Steel MST-BAR cost at 75 years is associated to Asphalt repair and concrete repair only and has nothing to do with reinforcement bar. Ref: Demonstrating the Economical Benefit of GFRP bars in Deck. CDCC2007(Confrence on Durability of FRP Composite for Construction

38 2800m 2 - Roof Slab Steel-Reinforced Deck-Initial Cost Description Quantity $/Unit Total Form Work 2800 m $/m 2 $ 336, Rebar & Installation 50,000 Kg 2.5 $/kg $ 125, Concrete (30MPa) & Installation t=254mm Area=2800 Volume=711m $/m 3 $ 177, Blast Track 2800 m $/m 2 $ 9, Water Proofing(Doubl e System) 2800 m 2 35 $/m 2 $ 98, Over Burden Asphalt 2800m 2 Gravel 2800m 2 27 $/m 2 11 $/m 2 $ 106, TOTAL $ 852,300.00

39 2800m 2 - Roof Slab Epoxy Coated Rebar-Reinforced Deck-Initial Cost Description Quantity $/Unit Total Form Work 2800 m $/m 2 $ 336, Rebar & Installation 50,000 Kg 3 $/kg $ 150, Concrete (30MPa) & Installation t=254mm Area=2800 Volume=711m $/m 3 $ 177, Blast Track 2800 m $/m 2 $ 9, Water Proofing(Doubl e System) 2800 m 2 35 $/m 2 $ 98, Over Burden Asphalt 2800m 2 Gravel 2800m 2 27 $/m 2 11 $/m 2 $ 106, TOTAL $ 877,300.00

40 2800m 2 - Roof Slab GFRP Rebar-Reinforced Deck-Initial Cost Description Quantity $/Unit Total Form Work 2800 m $/m 2 $ 336, Rebar & Installation 42,160m 3-6 $/m $ 211, Concrete (30MPa) & Installation t=200mm Area=2800 Volume=560m $/m 3 $ 140, Blast Track 2800 m $/m 2 $ 9, Water Proofing(Single System) 2800 m 2 20 $/m 2 $ 56, Over Burden Asphalt 2800m 2 27 $/m 2 $ 75, TOTAL $ 827,700.00

41 3 Options- 2800m 2 Parking Deck It should be noted that the life expectancy of structured reinforced with MST-BAR is 150 years Black Steel-Reinforced Deck-Initial Cost Epoxy Coated Rebar-Reinforced Deck-Initial Cost $ 852, $ 877, GFRP Reinforced- Deck-Initial Cost $ 827,700.00

42 BLACK Steel REPAIR!!! 2800m 2 Roof Slab Steel-Reinforced Deck- 35%(ONLY TOP SLAB CONSIDERED, NO THROUGH SLAB OR UNDER SIDE REPAIR) 4 (101MM) TOP SLAB 25 TO 30 YEARS REPAIR, CONSIDERING 0% INFLATION!!! RE&RE:REMOVAL & REPLEACMENET Description Quantity $/Unit Total Concrete demolition Rebar & Installation Concrete (30MPa) & Installation 980 m $/m 2 $ 122, ,000 Kg ONLY 20% TOP t=101mm Area=980 m 2 Volume=100 m $/kg $ 12, $/m 3 $ 25, Blast Track 2800 m $/m 2 $ 9, Water Proofing(Double System)(RE&RE) 2800 m 2 35 $/m 2 REM. 6 $/m 2 $ 114, Over Burden Asphalt 2800m 2 Gravel 2800m 2 54 $/m 2 11 $/m 2 $ 182, TOTAL $ 465,830.00

43 Epoxy Coated Steel REPAIR!!! 2800m 2 Roof Slab Epoxy coated- Reinforced Deck- 35%(ONLY TOP SLAB CONSIDERED, NO THROUGH SLAB OR UNDER SIDE REPAIR) 4 (101MM) TOP SLAB 25 TO 30 YEARS REPAIR, CONSIDERING 0% INFLATION!!! RE&RE:REMOVAL & REPLEACMENET Description Quantity $/Unit Total Concrete demolition Rebar & Installation Concrete (30MPa) & Installation 980 m $/m 2 $ 122, ,000 Kg ONLY 20% TOP t=101mm Area=980 m 2 Volume=100 m 3 3 $/kg $ 15, $/m 3 $ 25, Blast Track 2800 m $/m 2 $ 9, Water Proofing(Double System)(RE&RE) 2800 m 2 35 $/m 2 REM. 6 $/m 2 $ 114, Over Burden Asphalt 2800m 2 Gravel 2800m 2 54 $/m 2 11 $/m 2 $ 182, TOTAL $ 468,330.00

44 MST-BAR NO REPAIR Required!!! 2800m 2 Roof Slab Epoxy coated- Reinforced Deck- 35%(ONLY TOP SLAB CONSIDERED) 4 (101MM) TOP SLAB 25 TO 30 YEARS REPAIR, CONSIDERIN 0% INFLATION!!! RE&RE:REMOVAL & REPLEACMENET Description Quantity $/Unit Total Concrete demolition Rebar & Installation Concrete (30MPa) & Installation 0 0 $/m 2 $ $/kg $ $/m 3 $ 0 Blast Track 0 0 $/m 2 $ 0 Water Proofing(Double System)(RE&RE) Over Burden Asphalt 2800m 2 Optional 35 $/m 2 $ 0 REM. 6 $/m 2 54 $/m 2 $ 151, TOTAL $ 151,200.00

45 Cost of 2800m 2 Parking Deck After years It should be noted that the life expectancy of structured reinforced with MST-BAR is 150 years Black Steel-Reinforced Deck-Initial Cost Epoxy Coated Rebar-Reinforced Deck-Initial Cost $ 1,318, $ 1,345, MST-BAR GFRP Reinforced- Deck- Initial Cost $ 827,700.00

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