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.     

Flexural Strengthening of Steel Bridges with High Modulus CFRP Strips

Acceptance of carbon fiber-reinforced polymer (CFRP) materials for strengthening concrete structures, together with the recent availability of higher modulus CFRP strips, has resulted in the possibility to also strengthen steel structures. Steel bridge girders and building frames may require strengthening due to corrosion induced cross-section losses or changes in use. An experimental study investigating the feasibility of different strengthening approaches was conducted. Large-scale steel-concrete composite beams, typical of bridge structures, were used to consider the effect of CFRP modulus, prestressing of the CFRP strips, and splicing finite lengths of CFRP strips. All of the techniques examined were effective in utilizing the full capacity of the CFRP material, and increasing the elastic stiffness and ultimate strength of the beams. Results of the experimental program were compared to an analytical model that requires only the beam geometry and the constitutive properties of the CFRP, steel, and concrete. This model was used to investigate the importance of several key parameters. Finally, an approach for design is proposed that considers the bilinear behavior of a typical strengthened beam to the elastic-plastic behavior of the same beam before strengthening.     

Repair of Cracked Steel Girders Connected to Concrete Slabs Using Carbon-Fiber-Reinforced Polymer Sheets

This paper presents the results of an experimental study on the repair of artificially damaged steel–concrete composite beams repaired using adhesively bonded carbon-fiber-reinforced polymer (CFRP) sheets. Eleven, 2 m long, beams composed of W150×22 steel sections with 465×75?mm concrete slabs were tested in four-point bending. Severe damage was first introduced in ten beams by saw cutting the tension flange completely at mid span, to simulate a fatigue crack or a localized severe corrosion. Standard modulus (SM) and high modulus (HM) CFRP sheets were then used to repair nine damaged beams. The length and number of CFRP layers applied to the cracked flange on the underside, or on both sides, were varied. Results showed that the damage had reduced flexural strength and stiffness by 60 and 54%, respectively. Nevertheless, CFRP-repaired beams achieved various levels of recovery, and in some cases, exceeded the original capacities. The strength of beams repaired with sheets, ranging in length from 8 to 97% of the span, varied from 46–116% of the original undamaged strength, whereas the stiffness range was 86–126% of original stiffness. SM-CFRP failed by debonding whereas HM-CFRP was ruptured. Bonding the sheets to both sides of the flange was not very advantageous over bonding to the underside only.     

Application of Fiber Reinforced Polymer Overlays to Extend Steel Fatigue Life

An experimental and analytical study was conducted to investigate the effectiveness of applying carbon fiber reinforced polymer (CFRP) overlays to steel fatigue tension coupons to prolong fatigue life. Specimens were either notched or center hole specimens and tested in uniaxial tension. Variables studied were CFRP system, bond length, bond area, one and two sided applications, and applications prior or subsequent to crack propagation. Two sided applications were very effective, prolonging fatigue life by as much as 115%. Similar application of CFRP materials subsequent to crack propagation extended the remaining fatigue life by approximately 170% without any other means of crack arrest. The method therefore showed promise as both a preventive technique and repair method. The epoxy performance was critical to the effectiveness of the system, with all failures initiated by debonding of the CFRP. Overlays were most effective when the system was applied directly to the potential crack trajectory. One-sided applications introduced bending and did not significantly improve performance. CFRP materials with a moderate modulus of elasticity performed best. FEM was performed to estimate stress factors and effectiveness of overlays.     

Acoustic Emission Characterization of Damage in Hybrid Fiber-Reinforced Polymer Rods

The development and testing of a pseudoductile hybrid fiber-reinforced polymer rod consisting of glass and carbon fibers is described. Two different hybrid forms were considered for the development of the hybrid rods, including (1) random dispersion of the glass and carbon fibers; and (2) a core-shell design with a glass fiber core protected by the carbon fiber shells. The mechanical properties of the hybrids were evaluated through uniaxial tension tests. The hybrid rods developed by way of the core-shell approach exhibited pseudoductile properties that included a yield point of 1,153 MPa and an ultimate strength of 1,191 MPa, with a strain of 3.5% at ultimate. The experimental program also included damage assessment by way of a single-channel fiber optic acoustic emission (AE) sensor. The acoustic emission technique was employed for real-time determination of the progressive damage due to rupture of fibers. Moreover, the spectral energies of the frequency spectrum from the AE signals were employed for assessment of the state of damage in the rods. The spectral energies distinguish between the carbon and glass fiber ruptures. This differentiation of signals provides information about the condition and the state of health of the hybrid rod.     

CFRP Rehabilitation of Concrete Frame Joints with Inadequate Shear and Anchorage Details

The research presented in this study involves full-scale experimental evaluation of carbon fiber-reinforced polymer (CFRP) rehabilitation for existing beam-column joints designed for gravity load with common pre-1970s deficient reinforcement details when subjected to cyclic loading. Numerous studies have demonstrated effectiveness of externally bonded fiber-reinforced polymer (FRP) materials for retrofitting the deteriorating RC structures. Although these materials are widely used in bridges, their applications in buildings have been somewhat limited. In particular, the experimental investigations on external FRP retrofit of deficient beam-column joints have not thoroughly been investigated and they are mainly on scaled-down specimens. The failure of these subassemblies, which possess lack of shear reinforcement within the joint core and shortly embedded positive beam reinforcement, would possibly result in catastrophic collapse of reinforced concrete frame structure during an earthquake event. Recognizing the urgent need to upgrade these structural subassemblies, the current investigation uses CFRP retrofit techniques to enhance the performance of such deficient joints. Experimental variables studied entail the developed CFRP retrofit configurations, and magnitude of the applied column axial load. Comparative analysis of the lateral loads versus drift hysteresis loops, stiffness degradation, and total dissipated energy curves of three as-built and three corresponding CFRP-retrofitted RC joints revealed that significant improvement in the shear capacity of the upgraded joints occurred. More importantly, the slippage of short embedded beam positive reinforcement into the joint was substantially controlled due to the developed CFRP retrofit. The results demonstrate the effectiveness of CFRP retrofit configurations in enhancing the structural performance of actual size connections.     

CFRP Composite Connector for Concrete Members

Steel plate connections are frequently used in tilt-up and precast concrete building construction to tie adjacent wall panels together for shear and overturning effects, and to provide continuous diaphragm chord connections for wind and seismic loading. These welded connectors perform poorly in regions of high seismicity and are vulnerable to corrosion. Until now, retrofit and repair strategies for in-plane shear transfer strengthening were limited to attaching steel sections across panel edges. In the present paper, an experimental program is described that utilizes carbon fiber reinforced plastic (CFRP) composites to develop a viable retrofit scheme for precast concrete shear walls and diaphragms. Nine full-scale precast wall panel assemblies with CFRP composite connectors have been tested. The results show that the CFRP composite connection is an effective solution for the seismic retrofit and repair of precast concrete wall assemblies and other precast concrete elements, such as horizontal diaphragms, that require in-plane shear transfer strengthening.     

Sensors to Monitor CFRP/Concrete Bond in Beams Using Electrochemical Impedance Spectroscopy

The use of inexpensive electrochemical impedance spectroscopy based sensor technology for nondestructive evaluation (NDE) of bond degradation between external carbon fiber-reinforced polymer (CFRP) reinforcement and concrete is examined. Copper tape on the surface of the CFRP sheet, stainless steel wire embedded in the concrete, and reinforcing bars were used as the sensing elements. Laboratory experiments were designed to test the capability of the sensors to detect the debonding of the CFRP from the concrete and to study the effect of short-term (humidity and temperature fluctuations) and long-term (freeze-thaw and wet-dry exposure and rebar corrosion) environmental conditions on the measurements. The CFRP sheet was debonded from the concrete, and impedance measurements were taken between various pairs of electrodes at various interfacial crack lengths. The dependence of the impedance spectra, and of the parameters obtained from equivalent circuit analysis, on the interfacial crack length was studied. Capacitance parameters in the equivalent circuit correlated strongly with the interfacial crack length and can be used to assess the global state of the bond between CFRP sheets and concrete. Impedance measurements taken between embedded wire sensors can be used to detect the location of debonded regions.     

Slender Steel Columns Strengthened Using High-Modulus CFRP Plates for Buckling Control

This paper presents the results of an experimental investigation into the behavior of slender steel columns strengthened using high-modulus (313?GPa), carbon fiber-reinforced polymer (CFRP) plates. Eighteen slender hollow structural section square column specimens, 44×44×3.2?mm, were concentrically loaded to failure. The effectiveness of CFRP was evaluated for different slenderness ratios (kL/r), namely, 46, 70, and 93. The maximum increases in ultimate load ranged from 6 to 71% and axial stiffness ranged from 10 to 17%, respectively, depending on kL/r. As kL/r reduced, the effectiveness of CFRP plates also reduced, and failure mode changed from CFRP plate crushing after occurrence of overall buckling, to debonding prior to, or just at, buckling. A simplified analytical model is proposed to predict the ultimate axial load of FRP-strengthened slender steel columns, based on the ANSI/AISC 360-05 provisions, which were modified to account for the transformed section properties and a failure criteria of FRP derived from the experimental results. It was shown that for a given FRP reinforcement ratio, there is a critical kL/r at the low end, below which FRP may not enhance the strength of the column.     

Development and Evaluation of an Adhesively Bonded Panel-to-Panel Joint for a FRP Bridge Deck System

A fiber-reinforced polymer (FRP) composite cellular deck system was used to rehabilitate a historical cast iron thru-truss structure (Hawthorne St. Bridge in Covington, Va.). The most important characteristic of this application is reduction in self-weight, which raises the live load-carrying capacity of the bridge by replacing the existing concrete deck with a FRP deck. This bridge is designed to HL-93 load and has a 22.86?m clear span with a roadway width of 6.71?m. The panel-to-panel connections were accomplished using full width, adhesively (structural urethane adhesive) bonded tongue and groove splices with scarfed edges. To ensure proper construction, serviceability, and strength of the splice, a full-scale two-bay section of the bridge with three adhesively bonded panel-to-panel connections was constructed and tested in the Structures Laboratory at Virginia Tech. Test results showed that no crack initiated in the joints under service load and no significant change in stiffness or strength of the joint occurred after 3,000,000 cycles of fatigue loading. The proposed adhesive bonding technique was installed in the bridge in August 2006.     

Rehabilitation of Cracked Aluminum Connections with GFRP Composites for Fatigue Stresses

The original design of existing aluminum overhead sign structures (OSS) did not consider fatigue as a limit state. Cracks propagate in the welds of the connection between the main chord and branches of OSS due to fatigue stresses caused by wind-induced vibration, which occasionally lead to complete fracture of the welds. A rehabilitation method for cracked aluminum welded connections using glass fiber-reinforced Polymer (GFRP) composites is investigated for its effectiveness under fatigue stresses. The results of constant amplitude fatigue tests for three types of aluminum connections from actual OSS are presented: (1) connections with no known cracks; (2) cracked connections rehabilitated with GFRP composites; and (3) connections with 90% of the weld removed and subsequently repaired with GFRP composites. The fatigue limits of the three connection types are established for four stress ranges including the constant amplitude fatigue limit threshold. The rehabilitated connections from OSS exceeded the fatigue limit of the aluminum welded connections with no known cracks. The repaired connections with 90% of the weld removed satisfied the constant amplitude fatigue limit threshold. A cumulative damage index is established which leads to a fatigue reduction factor for the rehabilitation design of cracked aluminum connections using the GFRP composites.     

Flexural Response of Steel Beams Strengthened with Partial-Length CFRP Plates

This paper presents the flexural behavior of rolled steel beams that were strengthened with partial-length, adhesive-bonded carbon fiber-reinforced polymer (CFRP) plates. The hybrid beams had two types of failure mode, depending on the length of the plate: (1) plate debonding in beams with short plates;?and (2) plate rupture at midspan in beams with long plates. The flexural behavior that was investigated includes the development of tensile stresses in the plate, the moment-curvature of the strengthened section, and the load-deflection of the strengthened beam. The analytical methods used include shear lag analysis, section analysis, and application of the virtual work principle. Agreement between the experimental results and the analytical predictions is discussed.     

Effective Bond Length of Carbon-Fiber-Reinforced Polymer Strips Bonded to Fatigued Steel Bridge I-Girders

After years in service, many steel girders have deteriorated to the point where fatigue cracks have initiated in the girders. In girders having cover plates that do not terminate in a compression region, a common type of crack initiates at the weld toe at the ends of the cover plate after being subjected to cyclic tensile loads due to traffic. The use of precured carbon-fiber-reinforced polymer (CFRP) laminates, adhered to the inside face of the girder tension flange, is one proposed method for repairing these cracked bridge girders. The main advantages of using CFRP laminates are their light weight and their durability, which result in ease of handling and maintenance. For the application of this rehabilitation method, it is important to determine the effective bond length for CFRP laminates adhered to the inside face of a cracked steel girder flange. Experimental tests using a new type of effective bond length test specimen were conducted in this research on several types of adhesives and precured CFRP laminates, in addition to several different bonding configurations. The minimum bond length required to achieve the maximum strength of the rehabilitation scheme for the materials investigated in this research was determined. The experimental results also indicated that an adhesive with relatively large ductility is required to redistribute the stresses successfully within the adhesive layer during increased loading. A simple analytical solution for the shear strain distribution in the adhesive layer was proposed for estimating the effective bond length, and the results were verified with computational analyses. Good agreement was found among the computational, analytical, and experimental results.     

Fatigue of Diagonally Cracked RC Girders Repaired with CFRP

Fiber-reinforced polymers (FRP) are becoming more widely used for repair and strengthening of conventionally reinforced concrete (RC) bridge members. Once repaired, the member may be exposed to millions of load cycles during its service life. The anticipated life of FRP repairs for shear strengthening of bridge members under repeated service loads is uncertain. Field and laboratory tests of FRP-repaired RC deck girders were performed to evaluate high-cycle fatigue behavior. An in-service 1950s vintage RC deck-girder bridge repaired with externally bonded carbon fiber laminates for shear strengthening was inspected and instrumented, and FRP strain data were collected under ambient traffic conditions. In addition, three full-size girder specimens repaired with bonded carbon fiber laminate for shear strengthening were tested in the laboratory under repeated loads and compared with two unfatigued specimens. Results indicated relatively small in situ FRP strains, laboratory fatigue loading produced localized debonding along the FRP termination locations at the stem-deck interface, and the fatigue loading did not significantly alter the ultimate shear capacity of the specimens.     

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.     

Full-Scale Experimental Investigation of Repair of Reinforced Concrete Interstate Bridge Using CFRP Materials

An experimental study is presented of the behavior of eight reinforced concrete bridge girders taken from a decommissioned Interstate bridge and retrofitted with three different carbon-fiber-reinforced polymer (CFRP) systems. Specimens were subjected to monotonic loading to failure with and without significant fatigue conditioning. Experimental observations indicated that intermediate crack-induced debonding was the dominant failure mode for monotonically loaded beams and that degradation of the CFRP-to-concrete interface was caused by fatigue conditioning. Conventional adhesive applied and near-surface mounted (NSM) CFRP systems behaved well under monotonic loads, with the NSM system exhibiting significantly greater ductility. Powder actuated fastener applied retrofit was observed to be less efficient, requiring a relative slip of the CFRP in order to engage the shear transfer mechanism of the fasteners. The application of current accepted design guidelines for FRP retrofit indicated that guidelines aimed at mitigating debonding failure appear to be appropriately conservative under monotonic loading conditions; however, a significant additional reduction in CFRP strain limits is required to account for even small levels of fatigue loading.     

Fatigue and Overloading Behavior of Steel–Concrete Composite Flexural Members Strengthened with High Modulus CFRP Materials

Due to corrosion and the continuous demand to increase traffic loads, there is a need for an effective system which can be used to repair and/or strengthen steel bridges and structures. This paper describes an experimental program, recently completed, to investigate the fundamental behavior of steel–concrete composite scaled bridge beams strengthened with new high modulus carbon fiber-reinforced polymer (HM CFRP) materials. The behavior of the beams under overloading conditions and fatigue loading conditions was studied as well as the possible presence of shear lag at the interface of the steel surface and the CFRP strengthening material. The test results are compared to an analytical model based on the fundamental principles of equilibrium and compatibility, to predict the behavior of the strengthened steel–concrete composite beams. Based on the findings of this research work, combined with other work in the literature, a design guideline is proposed for the use of HM CFRP for strengthening the steel flexural members typically used for bridges and structures.     

Fatigue Performance of CFRP Strengthened RC Beams under Environmental Conditioning and Sustained Load

Carbon fiber-reinforced polymers (CFRPs) have become increasingly important in recent years in bridge rehabilitation. Significant research has been done on the static behavior of CFRP-strengthened reinforced concrete (RC) structures; however, the fatigue behavior of such structures with interface defects subjected to harsh environmental conditions still needs to be investigated. Hence, an experimental program has been carried out to investigate the fatigue behavior, under a load range, which generates service load stress levels, of RC beams strengthened with CFRP fabrics. The effect of aggressive environments was studied by subjecting the test members to freeze–thaw, extreme temperature, ultraviolet light exposure, and relative humidity cycles. All beams survived 2 million fatigue cycles without showing significant bond degradation between composite and substrate. However, significant flexural stiffness degradation was observed in the conditioned specimens. The presence of defects also affected specimen stiffness; however, limited growth in defect size was observed due to fatigue cycling.     

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.     

Modeling of an Unbonded CFRP Strap Shear Retrofitting System for Reinforced Concrete Beams

A retrofitting technique has been developed that uses carbon fiber-reinforced polymer (CFRP) straps to increase the shear capacity of reinforced concrete beams. The vertical straps are not bonded to the beam but are instead anchored against the beam, which makes this technique potentially more effective than bonded FRP retrofitting techniques. However, it also means that models for bonded FRPs are not appropriate for use with the straps. Instead, a model based on a shear friction approach has been developed where the strain in the straps is calculated based on a term that accounts for the effects of prestress and additional strain in the strap due to shear crack opening. The model can either consider the shear reinforcement to be smeared along the length of the beam or discrete elements. The “smeared” model was checked against an experimental database consisting of rectangular, T-, and deep beams, both in terms of predicted capacity and predicted strain in the straps. Overall the smeared model predicted the capacity of the specimens and, with some adjustments, the strains quite accurately. There were, however, cases when it was more appropriate to use the “discrete” model such as when the transverse reinforcement ratio was low or when the transverse reinforcement spacing was high. Further experimental data are required to fully validate the models and to determine appropriate limits on the use of the smeared model and the discrete model. However, the initial results are promising.