Strengthening of Reinforced Concrete Bridge Decks Using Carbon Fiber-Reinforced Polymer Composite Materials

This paper presents the results of an investigation of the monotonic and fatigue behavior of one-way and two-way reinforced concrete slabs strengthened with carbon fiber-reinforced polymer (CFRP) materials. The five one-way slab specimens were removed from a decommissioned bridge in South Carolina. Three of the slabs were retrofitted with CFRP strips bonded to their soffits and the other two served as unretrofit, control specimens. Of the five one-way slab specimens, one unretrofit and two retrofit slabs were tested monotonically until failure. The remaining two specimens, one unretrofit and one retrofit, were tested under cyclic (fatigue) loading until failure. In addition, six half-scale, two-way slab specimens were constructed to represent a full-scale prototype of a highway bridge deck designed using the empirical requirements of the AASHTO LRFD Bridge Design Manual. Of the six square slabs, two were unretrofitted and served as the control specimens, two were retrofitted using CFRP strips bonded to their soffits making a grid pattern, and two were retrofitted with a preformed CFRP grid material bonded to their soffit. Three slabs, one unretrofit, one CFRP strip, and one CFRP grid retrofitted, were tested monotonically until failure and the remaining three slabs were tested under cyclic (fatigue) loading until failure.     

Comparison of Three Flexural Retrofit Systems under Monotonic and Fatigue Loads

The majority of experimental work involving the flexural retrofit of concrete bridge girders has been conducted on beam specimens with adhesive-applied, soffit-mounted, fiber-reinforced polymer (FRP) composite systems, referred to in this study as conventional adhesive application (CAA). It has been observed that the performance of such girders is often controlled by the quality of the bond between the FRP and the concrete substrate and the substrate’s ability to transfer stress from the steel to the FRP. With the goal of improving the performance of bonded FRP in mind, two additional soffit-mounted retrofit schemes are investigated: near-surface mounted (NSM), where the FRP strips are embedded in adhesive within slots cut into the substrate concrete, and, powder-actuated fastener-applied (PAF) FRP, which uses a powder-actuated nail gun to install mechanical fasteners through predrilled holes in the FRP into the concrete substrate, “nailing” the FRP in place. The PAF application is a recent development, and little work has been done on it other than by the proprietors of the system. This study reports on a comparative study of the static and fatigue performance of reinforced concrete beams retrofitted with CAA, NSM, and PAF FRP retrofit systems. Ten medium-scale beams were tested: six strengthened specimens, two per retrofit method, were tested under cyclic loading conditions, and four specimens, one per retrofit method and one control specimen, were tested monotonically to failure. The results of this study indicate that although all three methods of FRP application result in significant strength increases over the control specimen under monotonic loading conditions, the CAA method is outperformed by the other methods under cyclic conditions. A number of other relevant detailed conclusions with respect to performance and practical application issues are presented for each of the methods of retrofit examined in this study. Significantly, clear evidence of FRP debonding in the midspan region prior to specimen failure is presented.     

Fatigue Behavior of RC Beams Strengthened with NSM CFRP Rods

This paper presents experimental results of reinforced concrete beams strengthened using near-surface mounted (NSM) carbon fiber-reinforced polymer (CFRP) reinforcement. A total of nine beam specimens were tested under fatigue loads. In addition, two specimens were tested for monotonic capacity. The beams were 3,500 mm long with a cross section of 254 mm deep by 152 mm wide. Different load ranges were considered in the fatigue tests to construct the fatigue life curves. The test results showed that under monotonic loading, the beam strengthened with NSM CFRP rod exhibited increases of 26 and 50% in the yield and ultimate load over the control beam, respectively. Under cyclic loading, the fatigue life for the strengthened beams was 24% higher than that of the control unstrengthened beams. An analytical model using sectional analysis and strain-life approach was developed to estimate the fatigue life of the specimens at various cyclic load ranges. A good agreement between the experimental results and analytical prediction of the fatigue life was obtained.     

Mechanism of Bond Behavior of Concrete Beams Strengthened with Near-Surface-Mounted CFRP Rods

Bond tests were conducted on concrete beams strengthened with near-surface-mounted (NSM) nonprestressed and prestressed carbon fiber-reinforced polymer (CFRP) rods under static loading. In the NSM technique, the CFRP rods are placed inside precut grooves and bonded to the concrete with epoxy adhesive. Six concrete beams were tested. The test variables included presence of internal tension steel reinforcement (unreinforced and reinforced), use of NSM CFRP strengthening (nonprestressed and prestressed), and type of CFRP rod (spirally wound and sand blasted). The beams were tested statically in four-point bending. Based on the test results, the transfer length for the prestressed CFRP rod in epoxied groove was 150 and 210 mm for the sand blasted and spirally wound rods, respectively. The main failure mode was debonding between the CFRP rod and the epoxy that starts at sections close to the midspan then, as the load increases, it propagates toward the supports. At failure, the beams strengthened with a given rod type showed the same CFRP strain at sections close to the support (29% of ultimate strain for spirally wound bars and 39% of ultimate strain for sand blasted bars). A cracked section analysis was carried out and compared well with the measured results.     

Fatigue Performance of Tension Steel Plates Strengthened with Prestressed CFRP Laminates

An experimental and analytical study was conducted to investigate the fatigue behavior of tension steel plates strengthened with prestressed carbon-fiber-reinforced polymer (CFRP) laminates. A simple fracture mechanics model was proposed to predict the fatigue life of reinforced specimens. Double-edge-notched specimens were precracked by fatigue loading and then strengthened by CFRP laminates at different prestressing levels. The effects of the applied stress range, CFRP stiffness, and prestressing level on the crack growth were investigated. Experimental results show that the increase of the prestressing level extends the fatigue life of a damaged steel plate to a large amount. The CFRP with the highest prestressing level performed best, prolonging fatigue life by as much as four times under 25% higher fatigue loading. Theoretically, predicted results were in a reasonable agreement with the experimental results. A parametric analysis was also performed to investigate the effects of the applied stress range and the prestressing level on the debonding behavior of the adhesive and on the secondary crack propagation.     

Debonding Failures of RC Beams Strengthened with Near Surface Mounted CFRP Strips

This paper presents the results of a series of tests conducted on reinforced concrete (RC) beams strengthened in flexure with near surface mounted (NSM) carbon fiber-reinforced polymer (CFRP) strips. As the main focus of the research is on debonding failure mechanisms, the only test variable investigated was the embedment length of the NSM strip and the NSM strip was extensively strain-gauged to monitor its bond behavior. Load-deflection curves, failure modes, strain distributions in the CFRP strip, and local bond stresses at the CFRP–epoxy interface from the tests are all examined in detail and compared with the predictions of a simple analytical model where appropriate. Of the four embedment lengths investigated, all but the shortest one led to a notable increase in the load-carrying capacity and, to a lesser extent, in the postcracking stiffness of the beam. Debonding was found to be the primary failure mode in all cases except for the beam with the longest embedment length. Also reported in this paper are results from preliminary bond tests used to characterize the local bond-slip behavior of the NSM system. Apart from gaining a better understanding of debonding failures in RC beams with NSM FRP strips, the test results reported in the paper should be useful for future verification of numerical and analytical models.     

Moving-Wheel Fatigue for Bridge Decks Strengthened with CFRP Strips Subject to Negative Bending

This paper presents the negative bending of reinforced concrete slabs strengthened with near-surface mounted (NSM) carbon fiber-reinforced polymer (CFRP) strips. Six slab specimens, three of which are strengthened with CFRP strips, are tested in static and fatigue loads. A wheel-running fatigue test machine is used to simulate vehicular loads on a bridge deck. The effectiveness of CFRP strengthening for bridge decks in cantilever and pseudonegative bending is examined based on moment-carrying capacity and cyclic behavior under the wheel-running fatigue loads, including crack patterns and damage accumulation. The moment-carrying capacity (static) of the cantilever slab strengthened with the NSM CFRP strips is improved by 68.4% when compared to that of an unstrengthened slab. The damage accumulation rate of the strengthened cantilever slab owing to the fatigue load is significantly lower than that of the unstrengthened slab. The damage accumulation of the strengthened slab gradually increases and is irreversible when the fatigue cycles increase. The fatigue-induced flexural cracks of the slabs develop along the wheel-running direction. A simple predictive model is presented to estimate the fatigue life of the test slabs.     

Behavior of Prestressed Concrete Strengthened with Various CFRP Systems Subjected to Fatigue Loading

Many prestressed concrete bridges are in need of upgrades to increase their posted capacities. The use of carbon fiber-reinforced polymer (CFRP) materials is gaining credibility as a strengthening option for reinforced concrete, yet few studies have been undertaken to determine their effectiveness for strengthening prestressed concrete. The effect of the CFRP strengthening on the induced fatigue stress ratio in the prestressing strand during service loading conditions is not well defined. This paper explores the fatigue behavior of prestressed concrete bridge girders strengthened with CFRP through examining the behavior of seven decommissioned 9.14?m (30?ft) girders strengthened with various CFRP systems including near-surface-mounted bars and strips, and externally bonded strips and sheets. Various levels of strengthening, prestressing configurations, and fatigue loading range are examined. The experimental results are used to provide recommendations on the effectiveness of each strengthening configuration. Test results show that CFRP strengthening can reduce crack widths, crack spacing, and the induced stress ratio in the prestressing strands under service loading conditions. It is recommended to keep the prestressing strand stress ratio under the increased service loading below the value of 5% for straight prestressing strands, and 3% for harped prestressing strands. A design example is presented to illustrate the proposed design guidelines in determining the level of CFRP strengthening. The design considers the behavior of the strengthened girder at various service and ultimate limit states.     

Fatigue Performance of RC Beams Strengthened in Shear with CFRP Fabrics

In recent years, a tremendous effort has been directed toward understanding and promoting the use of externally bonded fiber-reinforced polymer (FRP) composites to strengthen concrete structures. Despite this research effort, studies on the behavior of beams strengthened with FRP under fatigue loading are relatively few, especially with regard to its shear-strengthening aspect. This study aims to examine the fatigue performance of RC beams strengthened in shear using carbon FRP (CFRP) sheets. It involves six laboratory tests performed on full-size T-beams, where the following parameters are investigated: (1) the FRP ratio and (2) the internal transverse-steel reinforcement ratio. The major finding of this study is that specimens strengthened with one layer of CFRP survived 5 million cycles, some of them with no apparent signs of damage, demonstrating thereby the effectiveness of FRP strengthening systems on extending the fatigue life of structures. Specimens strengthened with two layers of CFRP failed in fatigue well below 5 million cycles. The failure mode observed for these specimens was a combination of crushing of the concrete struts, local debonding of CFRP, and yielding of steel stirrups. This failure may be attributed to the higher load amplitude and also to the greater stiffness of the FRP which may have changed the stress distribution among the different components coming into play. Finally, comparison between the performance of specimens with transverse steel and without seems to indicate that the addition of transverse steel extends the fatigue life of RC beams.     

Stable partial debonding of the cement interfaces indicated by a finite element model of a total hip prosthesis

A simplified three-dimensional finite element model of the femoral component of a cemented total hip prosthesis was used to investigate whether partial debonding at the stem-cement or bone-cement interfaces propagates in a stable or unstable manner, and to assess the resultant variation of the stresses within the cement layer. The likelihood of unstable debonding under tensile failure mode was assessed both by a conventional monotonic strength criterion and by a fracture mechanics approach that took into account debonding due to fatigue loading. The model predicted that partial debonding at the cement interfaces would be stable and would not precipitate complete debonding. Among the various bonding conditions that were investigated, the maximum tensile stress within the cement layer was least with a small amount of debonding rather than with complete bonding. These results were consistent with clinical observations of nonprogressive or slowly progressive separation at cement interfaces in cemented femoral components that were otherwise well functioning and asymptomatic.     

CFRP-Strengthened and Corroded RC Beams under Monotonic and Fatigue Loads

An experimental program has been carried out to investigate the structural behavior of RC beams strengthened by carbon-fiber–reinforced polymer (CFRP) sheets and exposed to a corrosive environment. A total of eight specimens (120 × 175 × 2,000 mm) were tested. Six specimens were CFRP strengthened and corroded, one specimen was unstrengthened and corroded, and one specimen was neither strengthened nor corroded. Two different strengthening schemes were applied: (1) wrapping the specimen with CFRP sheets; and (2) both specimen wrapping and flexural strengthening. Three specimens were tested under monotonic loading and five specimens were tested in fatigue. The results showed that the use of CFRP sheets for strengthening RC beams that are experiencing steel reinforcement corrosion is an efficient technique that can maintain the structural integrity and enhance the structural behavior of such beams. The ultimate monotonic strength of the CFRP strengthened-corroded specimens increased to a level between 37 and 87% above the predicted strength of a similar unstrengthened-uncorroded (virgin) specimen. The fatigue life of the CFRP strengthened-corroded specimens was increased within a range of 2.5–6.0 times that of a similar unstrengthened-corroded specimen but was lower than that of the uncorroded (virgin) specimen.     

Full-Scale Tests of Seismic Cable Restrainer Retrofits for Simply Supported Bridges

Many parts of the central and southeastern United States have recently begun initiating seismic retrofit programs for bridges on major interstate highways. One of the most common retrofit strategies is to provide cable restrainers at the intermediate hinges and abutments in order to reduce the likelihood of collapse due to unseating. To evaluate the force-displacement behavior of the cable restrainer retrofits, a full-scale bridge setup was constructed based on an existing multispan, simply supported steel girder bridge in Tennessee, that has been considered for seismic retrofit using cable restrainers. Seismic cable restrainers were connected to the bridge pier using steel bent plates, angles, and undercut anchors embedded in the concrete as specified by typical bridge retrofit plans. The full-scale bridge model was subjected to monotonic loading to test the capacity of the cable restrainer system and to determine the modes of failure. The results showed that the primary modes of failure are in the connection elements of the pier and girders, and they occur at force levels much lower than the strength of the cable. Modifications to the connection elements were designed and tested. The new connections resulted in a higher strength and deformation capacity of the cable restrainer assembly.     

Structural Performance of CFRP-Strengthened RC Slabs in a Corrosive Environment

This study was undertaken to address the effect of the main steel corrosion on the structural performance of RC slabs strengthened with carbon-fiber-reinforced polymer (CFRP) strips and exposed to a corrosive environment. A total of eight specimens (500×100×1,500?mm) were constructed and tested under monotonic static loading. Three specimens were CFRP-strengthened and corroded, three specimens were CFRP-strengthened and kept at room temperature, one specimen was unstrengthened and corroded, and one specimen was neither strengthened nor corroded. Three different strengthening schemes were applied: (1) externally bonded CFRP strips; (2) externally bonded CFRP strips provided with CFRP anchors; and (3) near surface mounted (NSM) CFRP strips. During the corrosion process, the specimens were placed in a small tank filled with sodium chloride (NaCl) solution concentration (3%) which covered only the slabs’ bottom third, and corrosion was induced by means of an impressed current. The corrosion process lasted for 20 days, and the average mass loss of the main steel reinforcement due to corrosion was 9%. Following corrosion, the specimens were tested under four-point bending. The experimental results showed that the increase in flexural capacity achieved using the three strengthening schemes were significantly reduced due to corrosion of the main steel. The recorded reductions in flexural strength gains for the CFRP-strengthened corroded slabs relative to the gains for the strengthened uncorroded slabs were about 55, 38, and 41% for the externally bonded CFRP system without anchors, externally bonded CFRP with anchors, and NSM-CFRP system, respectively.     

Fatigue Behavior of Externally Strengthened Concrete Beams with Fiber-Reinforced Polymers: State of the Art

This paper presents the recent progress and achievement in the application of fiber-reinforced polymers (FRP) on strengthening reinforced/prestressed concrete beams subjected to fatigue loading. Although the performance of FRP-strengthened structures under monotonic loading has been intensively investigated, fatigue behavior is relatively less known to date. This paper summarizes most of the currently available literature, including the codes and design manuals, on reinforced/prestressed concrete beams externally strengthened with FRP. The review focuses specifically on the fatigue life as a function of the applied load range, bond behavior of externally bonded FRP, damage accumulation, crack propagation, size effects, residual strength, and failure modes. Research needs including considerations for design guidelines are presented.     

Debonding Strength of Steel Beams Strengthened with CFRP Plates

This paper addresses the debonding strength of partial-length, adhesively bonded carbon fiber-reinforced polymer (CFRP) plates that are used to strengthen steel beams. Bonded CFRP plates tend to debond under static and fatigue loadings because of the very high stress field at the plate end. Such failures limit the application of CFRP plates. Static and fatigue tests show that the stress intensity factor governs the debonding strength. The steel/adhesive corner was the locus of debond initiation. The effects of the following parameters on stress intensity factors are discussed: plate thickness, plate modulus, bondline thickness, adhesive modulus, and adhesive spew-fillet angle. The stress intensity factors are calculated using the Betti’s law-based reciprocal work contour integral method (RWCIM). The parametric study results indicate that the stress intensity factors cannot be used to represent the severity of the corner as the adhesive spew-fillet angle (and singularity) changes. Therefore, the use of stress intensity factors as a failure criterion for the purpose of predicting debonding strength is limited to the same spew-fillet angle.     

RC Slabs Strengthened with Prestressed and Gradually Anchored CFRP Strips under Monotonic and Cyclic Loading

This paper presents the test results of reinforced concrete slabs strengthened with prestressed and gradually anchored carbon fiber–reinforced polymer (CFRP) strips under monotonic and cyclic loading. To take full advantage of the externally bonded CFRP technique, it is beneficial to apply the laminates in a prestressed state, which relieves the stress in the steel reinforcement and reduces crack widths and deflection. The aim of the monotonic tests was to determine the strengthening efficiency of the new prestressing technique and to investigate serviceability and ultimate states. The cyclic tests were performed to identify the fatigue behavior of the strengthened slabs and to investigate the influence of long-term cyclic loading and elevated temperature on the bond properties of the prestressed CFRP laminates and the ductility and flexural strength of the strengthened slabs. A nonlinear analytical model of reinforced concrete members strengthened with passive and prestressed CFRP strips under static loading is proposed in the paper. A comparison of the experimental and predicted results reveals an excellent agreement in the full range of loading.     

Fatigue and creep of a constrained metal wire

An experimental investigation has been conducted to examine the enhancement of toughness of composites due to crack bridging under creep and fatigue conditions. The model composite used for the study consists of a metal wire inside a thick-walled glass tube. It is found that the fatigue and the creep resistance of the constrained wire depends upon the failure mechanism. Compared with the unconstrained monolithic wire, the model composite shows greater fatigue and creep strengths due to plastic constraint. The failure stretch of the constrained wire is less for fatigue loading than for monotonic loading; the contribution to toughening is thus reduced under cyclic loading. The failure stretch in creep is dependent only upon the failure mechanism and not upon the applied stress level.     

Fatigue Behavior and Retrofit Investigation of Distortion-Induced Web Gap Cracking

This paper studies a Kansas Department of Transportation welded plate girder bridge that developed fatigue cracks at small web gaps close to the girder top flange. Repair had been previously performed by softening the connection plate end with a slot retrofit, but cracks were recently found to have reinitiated at some of the repaired details and are again propagating. A comprehensive finite-element method study was performed to investigate the cracking behavior observed in the bridge and to recommend appropriate measures for future bridge retrofit. The analytical results show that stresses developed at the top flange web gaps could exceed yielding under the loading of an HS15 fatigue truck. The current slot repair used in the bridge was found to have introduced higher magnitude fatigue stresses in the web gap. To achieve a permanent repair of the bridge, it is recommended that a welded connection plate to flange attachment be used during future bridge retrofit. The web gap details should be able to withstand unlimited number of load cycles once this additional repair is performed.     

Effect of Partial Unbonding on Prestressed Near-Surface-Mounted CFRP-Strengthened Concrete T-Beams

The flexural behavior of RC T-beams strengthened with prestressed near-surface-mounted (NSM) carbon fiber-reinforced-polymer (CFRP) reinforcement was investigated. The specific objective was to study the effect of partial unbonding of the CFRP reinforcement on the beam flexural behavior to increase the deformability. A total of eight RC T-beams were tested under four-point monotonic loading. The main variables were the level of prestressing force in the CFRP bars and the unbonded length at the midspan of the beam. The test results showed that all of the prestressed strengthened beams effectively improved the ultimate load-carrying capacity and the serviceability performance compared to the unstrengthened beam. The partially bonded prestressed beams exhibited an enhancement of the deformability compared to the fully bonded beams while minimizing the reduction of the load-carrying capacity. Partial unbonding was more effective to improve the deformability at higher levels of prestressing force. The general behavior of the partially bonded beams was reasonably well predicted by an analytical model developed previously by the writers.     

Investigation of Bond in Concrete Structures Strengthened with Near Surface Mounted Carbon Fiber Reinforced Polymer Strips

Fiber reinforced polymer (FRP) materials are currently produced in different configurations and are widely used for the strengthening and retrofitting of concrete structures and bridges. Recently, considerable research has been directed to characterize the use of FRP bars and strips as near surface mounted reinforcement, primarily for strengthening applications. Nevertheless, in-depth understanding of the bond mechanism is still a challenging issue. This paper presents both experimental and analytical investigations undertaken to evaluate bond characteristics of near surface mounted carbon FRP (CFRP) strips. A total of nine concrete beams, strengthened with near surface mounted CFRP strips were constructed and tested under monotonic static loading. Different embedment lengths were used to evaluate the development length needed for effective use of near surface mounted CFRP strips. A closed-form analytical solution is proposed to predict the interfacial shear stresses. The model is validated by comparing the predicted values with test results as well as nonlinear finite element modeling. A quantitative criterion governing the debonding failure of near surface mounted CFRP strips is established. The influence of various parameters including internal steel reinforcement ratio, concrete compressive strength, and groove width is discussed.