Strengthening steel bridge sections using CFRP laminates

This paper presents results from an experimental investigation to determine the feasibility of using carbon fiber reinforced polymer (CFRP) epoxy laminates to repair steel composite bridge members. Six specimens, each consisting of a 6.1 m long W8×24 wide flange A36 steel beam acting compositely with a 0.114 m thick by 0.71 m wide reinforced concrete slab, were first loaded past yield of the tension flange to simulate severe service distress. The damaged specimens were then repaired using 3.65 m lengths of 2 or 5 mm thick CFRP laminates bonded to the tension flange and tested to failure. The results indicated significant ultimate strength gains but more modest improvement in the elastic response. Non-linear finite element analyses were in good agreement with the experimental results. The study suggests that it is feasible to strengthen steel composite members using CFRP laminates.     

Electrostatic self-assembled carbon nanotube/nano carbon black composite fillers reinforced cement-based materials with multifunctionality

Electrostatic self-assembled carbon nanotube (CNT)/nano carbon black (NCB) composite fillers are added into cement mortar to fabricate smart cement-based materials. The grape bunch structure of CNT/NCB composite fillers is beneficial for dispersing CNT/NCB in cement mortar matrix and achieving cooperative improvement effect. The mechanical, electrically conductive, and piezoresistive behaviors of the cement mortar are investigated. The CNT/NCB composite fillers can effectively enhance the flexural strength and electrical conductivity of cement mortars, and endow stable and sensitive piezoresistivity to cement mortar at a low filler content. However, they weaken the compressive strength of cement mortar to some extent. The percolation threshold zone of cement mortar with CNT/NCB composite fillers ranges in the amount of 0.39–1.52 vol.%. The optimal content of CNT/NCB composite fillers is 2.40 vol.% for piezoresistivity and the stress and strain sensitivities can reach 2.69% MPa⁻¹ and 704, respectively.     

Load and resistance factor design of fiber reinforced polymer composite bridge deck

The majority of our bridges were constructed with conventional civil engineering materials of steel and concrete in a typical slab on girder or truss construction. Reinforced concrete bridge decks have approximately 40% life of the steel girders that support these structures. In order to support the use of alternative materials to replace deteriorating concrete decks, this paper outlines the Load and Resistance Factor Design (LRFD) of Fiber Reinforced Polymer composite (FRP) panel highway bridge deck. The deck would be of a sandwich construction where 152.4 mm × 152.4 mm × 9.5 mm square pultruded glass FRP (GFRP) tubes are joined and sandwiched between two 9.5 mm GFRP plates. The deck would be designed by Allowable Stress Design (ASD) and LRFD to support AASHTO design truckload HL-93. There are currently no US standards and specifications for the design of FRP pultruded shapes including a deck panel therefore international codes and references related to FRP profiles will be examined and AASHTO-LRFD specifications will be used as the basis for the final design. Overall, years of research and laboratory and field tests have proven FRP decks to be a viable alternative to conventional concrete deck. Therefore, conceptualizing the design of FRP bridge decks using basic structural analysis and mechanics would increase awareness and engineering confidence in the use of this innovative material.     

Microstructure and mechanical performance of modified mortar using hemp fibres and carbon nanotubes

Mechanical performance of modified mortar using hemp fibres is studied following various processing conditions. Hemp fibres combined with carbon nanotubes (CNT) are introduced in mortar and their effect is studied as function of curing time. The cement phase is replaced by different percentages of dry or wet hemp fibres ranging from 1.1 wt% up to 3.1 wt% whereas carbon nanotubes are dispersed in the aqueous solution. Our experimental results show that compressive and flexural strengths of wet fibres modified mortar are higher than those for dry hemp-mortar material. The achieved optimal percentage of wet hemp fibres is 2.1 wt% allowing a flexural strength higher than that of reference mortar. The addition of an optimal CNT concentration (0.01 wt%) combined with wet hemp has a reinforcing effect which turns to be related to an improvement of compressive and flexural strengths by 10% and 24%, respectively, in comparison with reference condition.     

Impact strength of a few natural fibre reinforced cement mortar slabs: a comparative study

This paper presents the experimental investigations of the resistance to impact loading of cement mortar slabs (1:3, size: 300 mm × 300 mm × 20 mm) reinforced with four natural fibres, coir, sisal, jute, hibiscus cannebinus and subjected to impact loading using a simple projectile test. Four different fibre contents (0.5%, 1.0%, 1.5% and 2.5%—by weight of cement) and three fibre lengths (20 mm, 30 mm and 40 mm) were considered. The results obtained have shown that the addition of the above natural fibres has increased the impact resistance by 3–18 times than that of the reference (i.e. plain) mortar slab. Of the four fibres, coir fibre reinforced mortar slab specimens have shown the best performance based on the set of chosen indicators, i.e. the impact resistance (R_u), residual impact strength ratio (I_rs), impact crack-resistance ratio (C_r) and the condition of fibre at ultimate failure.     

Partial transient liquid phase diffusion bonding of Zircaloy-4 to stabilized austenitic stainless steel 321

An innovative method was applied for bonding Zircaloy-4 to stabilized austenitic stainless steel 321 using an active titanium interlayer. Specimens were joined by a partial transient liquid phase diffusion bonding method in a vacuum furnace at different temperatures under 1 MPa dynamic pressure of contact. The influence of different bonding temperatures on the microstructure, microindentation hardness, joint strength and interlayer thickness has been studied. The diffusion of Fe, Cr, Ni and Zr has been investigated by scanning electron microscopy and energy dispersive spectroscopy elemental analyses. Results showed that control of the heating and cooling rate and 20 min soaking at 1223 K produces a perfect joint. However, solid-state diffusion of the melting point depressant elements into the joint metal causes the solid/liquid interface to advance until the joint is solidified. The tensile strength of all the bonded specimens was found around 480–670 MPa. Energy dispersive spectroscopy studies indicated that the melting occurred along the interface of the bonded specimens as a result of the transfer of atoms between the interlayer and the matrix during bonding. This technique provides a reliable method of bonding zirconium alloy to stainless steel.     

Effect of curing conditions on strength development in an epoxy resin for structural strengthening

Civil structures such as bridges and buildings can be strengthened with prestressed fibre reinforced polymer (FRP) strips to enhance both their stiffness and load-bearing capacity. End anchorage is a crucial issue for prestressed FRP strips. An innovative anchorage procedure, called the “gradient anchorage method” and based on the possible accelerated curing of the epoxy-resin in the end region of the FRP strip, has recently been conceived with the aim of avoiding more invasive mechanical fastening systems. An in-depth knowledge of the actual development of the key mechanical properties of resins under different curing conditions (i.e., in terms of curing temperature) is of paramount importance for employing the above mentioned gradient method in practical applications. This paper presents experimental results and analytical investigations aimed at developing a better understanding of the strength development of a commercial adhesive under different curing times and temperatures. Firstly, direct tensile tests on epoxy specimens were performed at different curing temperatures. It was shown that the necessary curing time to reach the maximum tensile strength can be significantly reduced from several hours at room temperature to approximately 30 min at 90 °C. Furthermore, higher curing temperatures reduced the activation time after which strength starts to increase. The experimental observations are shown graphically with both the activation time and reaction duration at different curing temperatures. Secondly, pull-off bond tests were conducted on 100 mm wide and 1.2 mm thick FRP strips bonded to concrete using epoxy adhesives cured either at 90 °C for different durations or at room temperature. An optical image correlation system (ICS) allowed the load transfer behaviour of the inhomogeneous cured adhesive between the FRP strip(s) and concrete to be studied. Finally, using the experimental measurements, the bond shear stress–slip interface relationships for the different test specimens were identified in order to present the effect of elevated curing temperatures and curing durations.     

Fire behaviour of reinforced concrete beams strengthened with CFRP laminates: Protection systems with insulation of the anchorage zones

This paper presents experimental and numerical investigations about the fire behaviour of reinforced concrete (RC) beams flexurally strengthened with carbon fibre reinforced polymer (CFRP) laminates. The main objective was to assess the efficacy of different fire protection systems and to evaluate the viability of their use in floors of buildings. Fire resistance tests were conducted on an intermediate scale oven to investigate the behaviour under fire (ISO 834) of loaded CFRP-strengthened RC beams. The fire protection systems comprised calcium silicate boards and layers of vermiculite/perlite cement based mortar, with thicknesses of 25 mm and 40 mm, applied along the bottom soffit of the beams that was directly exposed to fire. In addition, the anchorage zones of the CFRP laminates were highly thermally insulated in order to evaluate the benefits of this particular constructive detail. Member deflection and temperatures throughout the midspan section were measured and recorded during the tests. When the strengthening system was left unprotected in the exposed length of the beam, the CFRP laminate anchorage debonded after about 23 min. When the above mentioned fire protection materials were applied in the exposed length of the beams, the strengthening system debonded after between 60–89 min (25 mm thickness) and 137-167 min (40 mm). Two-dimensional finite element thermal models of all beams tested were also developed in order to predict the evolution of temperatures in the materials. The calculated temperatures compared reasonably well with those measured in the tests.     

Quasi-static and dynamic mechanical elastic moduli of alkaline aged pultruded fibre reinforced polymer composite rebar

Due to the increased use of glass fibre reinforced polymer composite (GFRP) rebar in concrete structures, the durability performance of GFRP rebar has been an important research topic in recent years. This paper presents elastic modulus of alkaline environment (pH ≈ 13) aged pultruded GFRP rebar as evaluated by three different methods, namely, quasi-static tensile, quasi-static flexural and dynamic mechanical thermal tests. It was found that elastic modulus of the GFRP rebar samples did not change significantly due to exposure in alkaline environment at 60 °C for 1, 2, 3, 4, 6 and 14 months when compared with that of control sample. Elastic modulus was found to be in the range of 52.5–56.5 GPa irrespective to testing methods and ageing time. In addition, it was estimated from the long time projected results that quasi-static tensile, quasi-static flexural and dynamic mechanical moduli will be retained by about 93%, 95% and 85%, respectively, after 100 years in alkaline environment at 60 °C. Microscopic analysis indicated that quasi-static tensile and flexural failure was mainly due to matrix cracking and shear failure of fibre/matrix interface.     

Statistical analysis for freeze–thaw resistance of cement mortars containing marble dust and glass fiber

This paper investigated the usability of marble dust and glass fiber against the harmful effects of freeze–thaw (FT) cycles on cement mortars as experimentally and statistically. To this end, the cement mortar specimens containing marble dust (0%, 20%, 40% and 50% by volume) and glass fiber (0 kg/m³, 0.25 kg/m³, 0.50 kg/m³, 0.75 kg/m³) were prepared. The compressive and flexural strengths of the specimens were determined after being exposed to FT cycles. In order to reduce the numbers of experiments, an L₁₆ (4² × 2¹) Taguchi orthogonal array was adopted to the study. Amounts of glass fiber, percentages of marble dust and cycles of freeze–thaw, were changed to explore their effects on the compressive and flexural strengths of the mortar specimens. Statistically effects of the factors were also determined by using analysis of variance (ANOVA) method. Finally, experimental findings were compared with statistical results and a good agreement between them was achieved.     

Post-cracking strength and ductility of glass–GFRP composite beams

This paper presents results of experimental and numerical investigations on the structural behaviour of composite beams made of annealed glass panes and glass fibre reinforced polymer (GFRP) pultruded profiles. The main goal of the transparent structural solutions presented here is to increase the post-cracking residual strength and ductility of glass by using GFRP strengthening laminates. The experimental programme included (i) tensile tests on double lap joints between glass and GFRP pultruded laminates, bonded with different types of structural adhesives, and (ii) full-scale flexural tests on glass beams and glass–GFRP composite beams, with different strengthening geometries and structural adhesives. Results obtained in this study show that, unlike glass beams, in glass–GFRP composite beams it is possible to obtain relatively ductile failure modes, with a significant increase of both strength and deformation capacity after the initial cracking of glass. The stiffness of the structural adhesive used, together with the geometry of the GFRP strengthening element, have a major influence on the structural response of the composite beams. Finite element models were developed for all tested beams, allowing to simulate their serviceability behaviour (prior to glass cracking) with fairly good accuracy, namely in what concerns the degree of shear interaction at the bonded interfaces.     

Performance of reinforced concrete slabs strengthened with different types and configurations of CFRP

A total of eight reinforced concrete slabs, 2440 × 600 × 125 mm strengthened with different layers and configurations of CFRP sheets were fabricated and tested. In addition, nonlinear finite element analysis (NLFEA) using ANSYS package was used to simulate the behavior of the test specimens. After reasonable validation of NLFEA with the experimental test results of companion slabs, NLFEA was expanded to provide a parametric study of eighteen slabs. The load–deflection, load strain, and failure modes obtained from the experimental test results and the NLFEA evidently confirmed that strengthening of under-reinforced concrete slabs with CFRP improves the flexural strength capacity and reduce the ductility. This was observed for both types of CFRP. The increase in the flexural strength and the reduction in the ductility increased with the increase in the number of CFRP layers. It was concluded that CFRP strengthening of slabs could be categorized as effective, economical, and successful only if substantial increase in the flexural strength capacity is achieved without changing the failure mode to a shear failure mode at the face of the supports or to a compression failure mode. Comparison between the two CFRP types, for almost equivalent applied area of CFRP, showed that the type of CFRP has significant influence on the behavior of the strengthened slabs. The difference is attributed to the difference in the mechanical properties and the bonding quality of the CFRP material.     

Mechanical properties of soil buried kenaf fibre reinforced thermoplastic polyurethane composites

A study on mechanical properties of soil buried kenaf fibre reinforced thermoplastic polyurethane (TPU) composites is presented in this paper. Kenaf bast fibre reinforced TPU composites were prepared via melt-mixing method using Haake Polydrive R600 internal mixer. The composites with 30% fibre loading were prepared based on some important parameters; i.e. 190 °C for reaction temperature, 11 min for reaction time and 400 rpm for rotating speed. The composites were subjected to soil burial tests where the purpose of these tests was to study the effect of moisture absorption on the mechanical properties of the composites. Tensile and flexural properties of the composites were determined before and after the soil burial tests for 20, 40, 60 and 80 days. The percentages of both moisture uptake and weight gain after soil burial tests were recorded. Tensile strength of kenaf fibre reinforced TPU composite dropped to ∼16.14 MPa after 80 days of soil burial test. It was also observed that there was no significant change in flexural properties of soil buried kenaf fibre reinforced TPU composite specimens.     

Behavior of full-scale reinforced concrete beams retrofitted for shear and flexural with FRP laminates

Four full-scale reinforced concrete beams were replicated from an existing bridge. The original beams were substantially deficient in shear strength, particularly for projected increase of traffic loads. Of the four replicate beams, one served as a control and the remaining three were implemented with varying configurations of carbon fiber reinforced polymers (CFRP) and glass FRP (GFRP) composites to simulate the retrofit of the existing structure. CFRP unidirectional sheets were placed to increase flexural capacity and GFRP unidirectional sheets were utilized to mitigate shear failure. Four-point bending tests were conducted. Load, deflection and strain data were collected. Fiber optic gauges were utilized in high flexural and shear regions and conventional resistive gauges were placed in eighteen locations to provide behavioral understanding of the composite material strengthening. Fiber optic readings were compared to conventional gauges.Results from this study show that the use of fiber reinforced polymers (FRP) composites for structural strengthening provides significant static capacity increases approximately 150% when compared to unstrengthened sections. Load at first crack and post cracking stiffness of all beams was increased primarily due to flexural CFRP. Test results suggest that beams retrofit with both the designed GFRP and CFRP should well exceed the static demand of 658 kN m sustaining up to 868 kN m applied moment. The addition of GFRP alone for shear was sufficient to offset the lack of steel stirrups and allow conventional RC beam failure by yielding of the tension steel. This allowed ultimate deflections to be 200% higher than the pre-existing shear deficient beam. If bridge beams were retrofit with only the designed CFRP failure would still result from diagonal tension cracks, albeit at a 31% greater load. Beams retrofit with only the designed shear GFRP would fail in flexure at the mid-span at an equivalent 31% gain over the control specimen, failing mechanism in this case being yielding of the tension steel. Successful monitoring of strain using fiber optics was achieved. However, careful planning tempered by engineering judgement is necessary as the location and gauge length of the fiber optic gauge will determine the usefulness of the collected data.     

Mechanical repair of timber beams fractured in flexure using bonded-in reinforcements

The flexural properties of strength class C16 spruce beams have been compared to the flexural properties of the same beams repaired with bonded-in reinforcements in the form of steel or composite pultruded rods. Reinforcing materials included rectangular sections of mild steel, pultruded carbon fibre reinforced plastic (CFRP), glass fibre reinforced plastic (GFRP) and a thermoplastic matrix glass fibre reinforced polyurethane (FULCRUM). Grooves were routed into the faces of the fractured beams following straightening and the reinforcements adhesively bonded into the top, bottom or both faces of the beams. The steel and CFRP reinforcements are most effective in restoring the flexural strength which often exceeds its original value. These reinforcements are also effective in enhancing flexural strength but the CFRP reinforcement endows the greatest transformed flexural strength. The fracture mechanisms in the repaired beams depend on the placement of reinforcement and the quality of the adhesive to reinforcement bond. All properties are optimised by bonding reinforcement into both faces of the fractured beams.     

Flexural properties loss of unidirectional epoxy/fique composites immersed in water and alkaline medium for construction application

Epoxy fique composites were evaluated for construction applications and compared with conventional wood used in construction. The composites studied were made with fique fibers treated using Na(OH) solution at 18 w/v%, untreated fique fibers were also used. The matrices were epoxy and epoxy with 5 wt.% of chemically modified C30B montmorillonite. Unidirectional composites of 90 mm × 20 mm × 4 mm were elaborated by pultrusion processing technique. The flexural properties loss occurred over 20 days of composites submitted to three types of environments: (i) water, (ii) saturated calcium hydroxide solution and (iii) mortar with w/c ratio of 0.45 and 540 kg/m³ of cement, cured in a saturated solution of lime stone at 50 °C. Results showed that fiber treatment and montmorillonite addition improved the flexural modulus and strength of composites in 40% and 34% respectively. Moreover the flexural properties of composites before and after ageing resulted comparable or even better than conventional wood used in construction.     

Structural nanocrystalline Ni coatings on periodic cellular steel

This study develops a new type of hybrid material that is a composite of a plain carbon steel micro-truss and a structural nanocrystalline Ni coating. The plain carbon steel micro-truss was made by a simple stretch–bend sheet forming method. It created a low density cellular material (～5% relative density), combining the low embodied energy and cost of the starting precursor material with the structural efficiency of pyramidal micro-truss architecture. The nanocrystalline Ni structural coating was designed to provide both corrosion protection and inelastic buckling resistance. Because the ultra-high strength material was optimally located at the furthest distance from the neutral bending axis, only a thin coating of nanocrystalline Ni (～50 μm) is needed to double the inelastic buckling resistance of the 1.13 mm × 0.63 mm plain carbon steel struts.     

Flexural properties loss of unidirectional epoxy/fique composites immersed in water and alkaline medium for construction application

Epoxy fique composites were evaluated for construction applications and compared with conventional wood used in construction. The composites studied were made with fique fibers treated using Na(OH) solution at 18 w/v%, untreated fique fibers were also used. The matrices were epoxy and epoxy with 5 wt.% of chemically modified C30B montmorillonite. Unidirectional composites of 90 mm × 20 mm × 4 mm were elaborated by pultrusion processing technique. The flexural properties loss occurred over 20 days of composites submitted to three types of environments: (i) water, (ii) saturated calcium hydroxide solution and (iii) mortar with w/c ratio of 0.45 and 540 kg/m³ of cement, cured in a saturated solution of lime stone at 50 °C. Results showed that fiber treatment and montmorillonite addition improved the flexural modulus and strength of composites in 40% and 34% respectively. Moreover the flexural properties of composites before and after ageing resulted comparable or even better than conventional wood used in construction.     

An assessment of mechanical behavior and fractography study of glass/epoxy composites at different temperatures and loading speeds

Effect of loading rate on fracture and mechanical behavior of autoclave cured glass fiber/epoxy prepreg composite has been studied at various loading (striking) rates (0.01-10³ mm/min). The maximum load carrying capacity and strain at yield continuously increases with increasing loading speed. The interlaminar shear strength (ILSS) value is high at low loading speed and becomes low at high loading speed with the transition of loading rate at approximately 300 mm/min. The formation of steps, welt interfacial failure and cleavage formation on matrix resin i.e. localized plastic deformation processes were dominating mechanisms for specimens tested at low loading rates, while brittle fracture of fiber, fiber pull-out and impregnation were dominating mechanisms for specimens tested at loading rates of 800 mm/min or higher.     

Strengthening of σ phase in a Fe20Cr9Ni cast austenite stainless steel

The strengthening mechanism of σ phase in a Fe20Cr9Ni cast austenite stainless steel used for primary coolant pipes of nuclear power plants has been investigated. The yield and ultimate tensile strengths of aged specimens increased comparing with those of the unaged ones. It was found that the increase of strengths is due to the hard and brittle (σ + γ₂) structure which decomposed from α phase in the steel. Fracture surfaces of specimens after in situ tensile test showed that the inhibition of (σ + γ₂) structure on the dislocation movements was more significant than ferrite although cracks started predominately at σ/γ₂ interfaces. The (σ + γ₂) structure behaves like a fiber reinforced composite material.