Evaluation of GFRP Honeycomb Beams for the O’Fallon Park Bridge

This paper presents a study on the evaluation of the static performance of a glass fiber-reinforced polymer (GFRP) bridge deck that was installed in O’Fallon Park over Bear Creek west of the City of Denver. The bridge deck has a sandwich panel configuration, consisting of two stiff faces separated by a light-weight honeycomb core. The deck was manufactured using a hand lay-up technique. To assist the preliminary design of the deck, the stiffness and load-carrying capacities of four approximately 330 mm (13 in.) wide GFRP beam specimens were evaluated. The crushing capacity of the panel was also examined by subjecting four 330×305×190?mm?(13×12×7.5?in.) specimens to compression tests. The experimental data were analyzed and compared to results obtained from analytical and finite element models, which have been used to enhance the understanding of the experimental observations. The failure of all four beams was caused by the delamination of the top faces. In spite of the scatter of the tests results, the beams showed good shear strengths at the face-to-core interface as compared to similar panels evaluated in prior studies.     

Dynamic Characteristics and Effective Stiffness Properties of Honeycomb Composite Sandwich Structures for Highway Bridge Applications

In this paper, a combined analytical and experimental study of dynamic characteristics of honeycomb composite sandwich structures in bridge systems is presented, and a relatively simple and reliable dynamic experimental procedure to estimate the beam bending and transverse shear stiffness is proposed. This procedure is especially practicable for estimating the beam transverse shear stiffness, which is primarily contributed by the core and is usually difficult to measure. The composite sandwich beams are made of E-glass fiber and polyester resins, and the core consists of the corrugated cells in a sinusoidal configuration. Based on the modeling of equivalent properties for the face laminates and core elements, analytical predictions of effective flexural and transverse shear stiffness properties of sandwich beams along the longitudinal and transverse to the sinusoidal core wave directions are first obtained. Using piezoelectric sensors, the dynamic response data are collected, and the dynamic characteristics of the sandwich structures are analyzed, from which the flexural and transverse shear stiffness properties are reduced. The experimental stiffness results are then compared to the analytical stiffness properties, and relatively good correlations are obtained. The proposed dynamic tests using piezoelectric sensors can be used effectively to evaluate the dynamic characteristics and stiffness properties of large sandwich structures suitable for highway bridge applications.     

Responses of damage and energy of sandwich and multilayer beams composed of metallic face sheets and aluminum foam core under bending loading

This present article deals with bending deformation and failure behavior of sandwich and multilayer beams composed of aluminum foam core and metallic face sheets analyzed byin-situ surface displacement analysis (SDA). The effect of beam structure on the failure mode of beam and the energy absorbed by beam failure were investigated and discussed. The SDA results revealed that collapse of the sandwich beams is by two basic modes, indentation (ID) and core shear (CS). The ID is localized deformation on the beam adjacent to the inner or outer roller in four-point bending, where displacement and compressive strains are at the maximum. As for CS mode, failure occurs in the core between inner and outer rollers, which corresponds to the maximum shear strain; discontinuous displacements in both the vertical and horizontal directions are the primary factors for shear crack initiation, growth, and broadening. The failure of the multilayer beams depends on whether the face sheets show ID mode or otherwise. If a single layer core sandwich fails in ID mode, the multilayer beams with similar face sheets show mixed ID + CS modes. If a single layer core sandwich fails fully in CS mode, no ID characteristic appears in the similar face sheet multilayer beams. The deformation energy of the beams relates strongly to the structure and geometry of beam. The predication of the bending fracture workW _x of a beam is given by

Mechanics of Composite Sinusoidal Honeycomb Cores

Lightweight and heavy-duty fiber-reinforced polymer (FRP) composite honeycomb sandwich structures have been increasingly used in civil infrastructure. Unique cellular core configurations, such as sinusoidal core, have been applied in sandwich construction. Due to specific core geometry, the solutions for core effective stiffness properties are not readily available. This paper presents a mechanics of materials approach to evaluate the effective stiffness properties of sinusoidal cores. In particular, the internal forces of a curved wall in a unit cell are expressed in terms of resultant forces, and based on the energy method and principle of equivalence analysis, the in-plane stiffness properties of sinusoidal cores are derived. Both finite-element modeling and experimental testing are carried out to verify the accuracy of the proposed analytical formulation. To illustrate the present analytical approach as an efficient tool in optimal analysis and size selection of sinusoidal cores, several design plots are provided and discussed. The simplified analysis and formulation presented for sinusoidal cores can be used in design application of FRP honeycomb sandwich and optimization of efficient cellular core structures.     

Steel Hexagonal Honeycomb Core Equivalent Elastic Moduli for Bridge Deck Sandwich Panels

Glass fiber-reinforced polymer (GFRP) materials possess inherently high strength-to-weight ratios, but their effective elastic moduli are low relative to civil engineering (CE) construction materials. While elastic modulus may be comparable to that of some CE materials, the lower shear modulus adversely affects stiffness. As a result, serviceability issues are what govern GFRP deck design in the CE bridge industry. An innovative solution to increase the stiffness of a commercial GFRP reinforced-sinusoidal honeycomb sandwich panel was proposed; this solution would completely replace the GFRP honeycomb core with a hexagonal honeycomb core constructed from commercial steel roof decking. The purpose of this study was to perform small-scale tests to characterize the steel hexagonal honeycomb core equivalent elastic moduli in an effort to simplify the modeling of the core. The steel core equivalent moduli experimental results were compared with theoretical hexagonal honeycomb elastic modulus equations from the literature, demonstrating the applicability of the theoretical equations to the steel honeycomb core. Core equivalent elastic modulus equations were then proposed to model and characterize the steel hexagonal honeycomb as applicable to sandwich panel design. The equivalent honeycomb core will enable an efficient sandwich panel stiffness design technique, both for structural analysis methods (i.e., hand calculations) and finite-element analysis procedures.     

Planar Bending of Sandwich Beams with Transverse Loads off the Centroidal Axis

Conventional analysis methods for beams do not distinguish between transverse loads that are applied at the beam centroidal axis and those acting either above or below the centroidal axis. In contrast, this paper formulates a sandwich beam finite element solution which models the effect of load height relative to the centroidal axis. Towards this goal, the governing equilibrium equations and associated boundary conditions are derived based on a Timoshenko beam formulation for the core material. Special shape functions satisfying the homogeneous form of the equilibrium equations are derived and subsequently used to formulate exact stiffness matrices. By omitting the stiffness terms related to the faces, the formulation for a homogeneous Timoshenko beam can be recovered. Also, the Euler–Bernouilli counterpart of the formulation is recovered as a limiting case of the current Timoshenko beam formulation. Effects of load height relative to the centroid are observed to have similarities with those induced by axial forces in beam-columns. For a simply supported beam, downward acting loads located below the centroidal axis are found to induce a stiffening effect while those acting above the centroidal axis are found to induce a softening effect, resulting in higher transverse displacements.     

Deformation and fracture behavior of beams composed of alumium foam core and ceramic Al<Subscript>2</Subscript>O<Subscript>3</Subscript> under monolithic bending

Deformation and fracture mechanisms of sandwich and multilayer beams composed of aluminum foam core and ceramic face sheets under four-point bending condition were investigated in situ by surface displacement analysis (SDA) software. The toughening mechanism of the beams was discussed and a model was given for the computation of the fracture energy of the beams. Beams containing foam core with 5-, 10-, and 20-mm thickness and Al₂O₃ face sheets of 0.5-and 1-mm thickness were prepared. The results show that collapse of the beams is by two basic modes, indentation (ID) and face plate failure (PF). The SDA results illustrated that indentation is localized compression on the portion of the beam adjacent to the loading rollers, where displacement and strain are at the maximum. In PF, the beam entirely bends. It is also found that before collapse of the beams with pure PF mode, the foam core undergoes uniform compressive deformation, which contributes most to the fracture energy of the beams. As for the beams with ID characteristic, the localized compressive deformation plays a key role rather than the uniform compressive deformation in the fracture energy of the beam. The total fracture energy W of a beam under bending condition is proposed as W=W _UC+W _LC+W _CB+W _PF where W _UCis the energy of uniform compressive deformation of the foam core, W _LCis the energy of localized compression of the foam core and W _CBand W _PFare the bending fracture energy of the monolithic foam core and ceramic face sheet, respectively. For the beams with pure PF mode, W _LCis zero. The estimated values of the fracture energy are in good agreement with the measured fracture energy of the beams.     

Global and Local Buckling of a Sandwich Beam

A two-dimensional mechanical model is developed to predict the global and local buckling of a sandwich beam, using classical elasticity. The face sheet and the core are assumed as linear elastic isotropic continua in a state of planar deformation. The core is assumed to have two deformation modes: antisymmetrical and symmetrical with respect to the core geometric midplane. Characteristics of the two deformation modes and the corresponding buckling behavior are shown and it appears that they are identical when the buckling wavelength is short. The present analysis is compared with various previous analytical studies and corresponding experimental results. On the basis of the model developed here, validation and accuracy of several previous theories are discussed for different geometric and material properties of a sandwich beam. The results presented in this paper, verified through finite-element analysis and experiment, are an accurate prediction of the overall buckling behavior of a sandwich beam, for a wide range of material and geometric parameters.     

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.     

Deformation and fracture behavior of beams composed of aluminum foam core and ceramic Al<Subscript>2</Subscript>O<Subscript>3</Subscript> under monolithic bending

Deformation and fracture mechanisms of sandwich and multilayer beams composed of aluminum foam core and ceramic face sheets under four-point bending condition were investigated in situ by surface displacement analysis (SDA) software. The toughening mechanism of the beams was discussed and a model was given for the computation of the fracture energy of the beams. Beams containing foam core with 5-, 10-, and 20-mm thickness and Al₂O₃ face sheets of 0.5- and 1-mm thickness were prepared. The results show that collapse of the beams is by two basic modes, indentation (ID) and face plate failure (PF). The SDA results illustrated that indentation is localized compression on the portion of the beam adjacent to the loading rollers, where displacement and strain are at the maximum. In PF, the beam entirely bends. It is also found that before collapse of the beams with pure PF mode, the foam core undergoes uniform compressive deformation, which contributes most to the fracture energy of the beams. As for the beams with ID characteristic, the localized compressive deformation plays a key role rather than the uniform compressive deformation in the fracture energy of the beam. The total fracture energy W of a beam under bending condition is proposed as

Adhesively Bonded and Translucent Glass Fiber Reinforced Polymer Sandwich Girders

An experimental program has been carried out to investigate the structural behavior of adhesively bonded glass fiber reinforced polymer (GFRP) sandwich girders. The girders, conceivable for main spans up to 20 m, are composed of translucent double sandwich element webs and adhesively bonded pultruded shape flanges. The continuous adhesive connections between web and flanges are loaded in a highly favorable manner without peeling stresses. Despite the complex load-carrying and failure behavior of the girders, simple calculation models can be applied. The successful girder experiments allowed for the development of a material-adapted construction method for new GFRP bridges and buildings. The integration of architectural aspects such as transparency, translucency, lighting, and color, as well as building physical aspects for buildings such as thermal insulation, substantially increases the overall value of the proposed constructions. Together with the lower life-cycle costs, this further justifies these new materials’ higher initial costs as compared with traditional materials.     

Crushing Ice Forces on Structures

On the basis of the results of small-scale and medium-scale indentation tests and full-scale measurements of ice forces, a methodology to estimate crushing ice forces is presented. The main point to note is that the effective pressure depends on the relative indentation speed, which in turn depends on the speed of a moving ice floe and the compliance of a structure. An increase in indentation speed leads to a change in failure mode from ductile to brittle, resulting in decreased effective pressure, and vice versa. The ice forces also depend on the temperature of the ice, because its strength and brittleness increase with decreasing temperature. The two codes for bridge piers and offshore structures are valid for brittle crushing of ice at high indentation speeds, and the recommended design effective pressure from these two codes is the same for wide structures (or large contact area) but differs for narrow structures (or small contact area).     

Thermomechanical Behavior of Multifunctional GFRP Sandwich Structures with Encapsulated Photovoltaic Cells

The feasibility of encapsulating solar cells into the glass fiber-reinforced polymer (GFRP) skins of load-bearing and thermally insulating sandwich elements with foam cores has been evaluated. Exposure of the encapsulated cells to artificial sunlight led to a significant temperature increase on the top sandwich surface, which almost reached the glass transition temperature of the resin. Mechanical loading up to serviceability limit loads did not cause any damage to the solar cells. Stresses of less than 20% of the material strength arose in the face sheets due to thermal and mechanical loading up to failure. Composite action through the face sheets with encapsulated cells was maintained and no debonding between face sheets and foam core was observed. Thanks to the superior mechanical and thermal sandwich behavior, thin-film silicon cells are more appropriate than polycrystalline silicon cells for use in multifunctional GFRP sandwich structures, although they are less efficient.     

Structural Model to Predict the Failure Behavior of Plated Reinforced Concrete Beams

This paper presents a theoretical model, based on truss analogy, to analyze the structural behavior at failure of reinforced concrete beams with steel plates or fiber-reinforced polymer lamitates bonded to their tension faces. The analytical approach, incorporated in the framework of strut-and-tie models, takes into account the nonlinear behavior of materials and of the structural member. In addition, it includes the load transfer mechanism to reflect the plate-debonding phenomenon and associated cracking of concrete cover, both of which play a critical role in the failure process of plated beams. The model, which takes into consideration all the possible failure modes of plated beams, is capable of predicting the beam load-carrying capacity at ultimate and, also, of indicating the associated mode of failure. It aims to develop a rational engineering analysis in a field which until now has been studied with linear elastic approaches or empirical methods. The proposed model has been validated by comparing the results obtained in the present analysis with over a hundred experimental results available in published literature. Furthermore, the results obtained with the present analysis are compared with those obtained by two other models, and it is shown that the model proposed here provides a consistent and satisfactory correlation with a wide range of reinforced concrete beam tests strengthened with steel or polymer composite plates.     

Asymmetric Low-Velocity Impact of a Finite Layer

The dynamic indentation of structural elements such as beams and plates continues to be an intriguing problem, especially for scenarios where large area contacts can occur. Standard methods of indentation analysis typically use a dynamic beam theory solution to obtain an overall load-displacement relationship and then a Hertzian contact solution to determine local stresses under the impactor. However, previous static and dynamic modeling efforts have shown that the stress distribution in the contact region will differ significantly from a Hertzian one when the contact length exceeds the thickness of the beam. In such cases point contact can no longer be assumed and Hertzian relationships are no longer valid. The dynamic indentation model presented herein is a first effort to model the asymmetric (i.e., off-center) low-velocity impact problem for elastically supported beams. Numerical results obtained are compared with elementary beam theory solutions for model validation.     

Numerical Simulations of Dynamic Instability of Elastic-Plastic Beams

This paper numerically investigates the dynamic instability of different elastic-plastic beams subjected to transverse pulse load. Two types of beam dynamic instability, i.e., symmetrical and asymmetrical instabilities, are studied. The unstable responses of the elastic-plastic beams are illustrated by investigating the modal participation factors of the lowest nine vibration modes, which are determined by inverse derivation of the numerically simulated beam deflection response. The critical pulse loads for the beam symmetrical and asymmetrical instabilities are obtained with respect to different load durations. Characteristic diagrams for beams with different boundary conditions and subjected to different type pulse loads are given. The present study conforms that not only axial compressive load induces instability of slender members, but also transverse pulse load results in instability of elastic-plastic beams.     

Flexural Behavior of Continuous FRP-Reinforced Concrete Beams

Continuous concrete beams are commonly used elements in structures such as parking garages and overpasses, which might be exposed to extreme weather conditions and the application of deicing salts. The use of the fiber-reinforced polymers (FRP) bars having no expansive corrosion product in these types of structures has become a viable alternative to steel bars to overcome the steel-corrosion problems. However, the ability of FRP materials to redistribute loads and moments in continuous beams is questionable due to the linear-elastic behavior of such materials up to failure. This paper presents the experimental results of four reinforced concrete beams with rectangular cross section of 200×300?mm continuous over two spans of 2,800 mm each. The material and the amount of longitudinal reinforcement were the main investigated parameters in this study. Two beams were reinforced with glass FRP (GFRP) bars in to different configurations while one beam was reinforced with carbon FRP bars. A steel-reinforced continuous concrete beam was also tested to compare the results. The experimental results showed that moment redistribution in FRP-reinforced continuous concrete beams is possible if the reinforcement configuration is chosen properly. Increasing the GFRP reinforcement at the midspan section compared to middle support section had positive effects on reducing midspan deflections and improving load capacity. The test results were compared to the available design models and FRP codes. It was concluded that the Canadian Standards Association Code (CSA/S806-02) could reasonably predict the failure load of the tested beams; however, it fails to predict the failure location.     

Impact Mechanics and High-Energy Absorbing Materials: Review

In this paper a review of impact mechanics and high-energy absorbing materials is presented. We review different theoretical models (rigid-body dynamics, elastic, shock, and plastic wave propagation, and nonclassical or nonlocal models) and computational methods (finite-element, finite-difference, and mesh-free methods) used in impact mechanics. Some recent developments in numerical simulation of impact (e.g., peridynamics) and new design concepts proposed as high energy absorbing materials (lattice and truss structures, hybrid sandwich composites, metal foams, magnetorheological fluids, porous shape memory alloys) are discussed. Recent studies on experimental evaluation and constitutive modeling of strain rate-dependent polymer matrix composites are also presented. Impact damage on composite materials in aerospace engineering is discussed along with future research needs. A particular example for the design of a sandwich material as an impact mitigator is given in more detail. This brief review is intended to help the readers in identifying starting points for research in modeling and simulation of impact problems and in designing energy absorbing materials and structures.     

Performance Evaluation of Repair Technique for Damaged Fiber-Reinforced Polymer Honeycomb Bridge Deck Panels

All-composite, fiber-reinforced polymer honeycomb (FRPH) sandwich panels are an innovative application of modern composite materials in civil engineering. These panels have become increasingly popular for use as full-depth bridge decks and have been used to span both transversely between steel or concrete girders and longitudinally between abutments. Although several bridges using FRPH panels have been installed in recent years, a method to repair the panels if they are damaged has not been thoroughly investigated. This paper presents the analysis and full-scale evaluation of a 9.75 m (32 ft) long FRPH member that was subjected to severe core-face delamination damage and subsequently repaired. As such, the work presented herein is the first of its kind to be conducted for FRPH bridge members. The damaged member when repaired was shown to have approximately 65% more capacity than a similar undamaged member. The additional capacity was achieved using a single wrapping layer over the face plates and sinusoidal core. This wrapping layer is believed to have prevented a failure (at the resin bond line) between the face plates and core by engaging a shear-friction type clamping force. The contribution of the wrap layer is considered using simple calculations, rigorous finite-element models, and experimental data. Acoustic emission monitoring was used to compare the performance of the damaged and repaired specimens under sustained load.     

Evaluation of fatigue damage in materials using indentation testing and infrared thermography

Damage identification due to fatigue has been studied on 304-Stainless Steel and Al-Cu-Mg alloys 2014-T651 and 7175-T7351, using two different experimental methods: a) cyclic indentation, and b) infrared thermography. Indentation response during load controlled cyclic loading is used to characterize fatigue response of materials. The load vs. depth of penetration data obtained continuously during fatigue testing is used to obtain information on cyclic stress-strain behavior and onset of failure. Infrared thermography is used to study the heat generation during fatigue loading on specimens. The variables that affect the process are: frequency of loading, magnitude of strain (elastic-plastic), thermal properties. The temperature curve can be considered to be having three regions, initial region of rapid increase in temperature, followed by stable temperature rise and final rapid heat generation prior to failure. The slopes in the initial region and stable region are independent of prior damage history in materials in case of specimens subjected to pure elastic load reversals. In case of elastic-plastic loadings, the rate at which the temperature rises in initial region changes as a function of fatigue damage and can thus be used to estimate prior damage in materials.