Light-Weight Fiber-Reinforced Polymer Composite Deck Panels for Extreme Applications

Currently within the military there is a need for a universal light-weight bridge deck system capable of supporting extreme loads over a wide temperature range. This research presents the development, testing, and analysis of five different fiber-reinforced polymer (FRP) webbed core deck panels. The performance of the FRP webbed decks are compared with an existing aluminum deck and with a baseline balsa core system, which has previously been tested as part of the development of the composite army bridge for the US Army. The study shows that for one-way bending, the FRP webbed core can exceed the shear strength of the baseline balsa core by a factor of 3.2 at a core’s density, which is 28% lighter than the balsa baseline. In addition, weight savings in excess of 30% are shown for using FRP decking in place of conventional aluminum decking. Based on test results and finite-element analysis, the failure modes of the different FRP webbed cores are discussed and design recommendations for FRP webbed core decks are provided.     

Close Look at Construction Issues and Performance of Four Fiber-Reinforced Polymer Composite Bridge Decks

Four different fiber-reinforced polymer (FRP) panel systems were installed in a 207 m, five-span, three-lane bridge in an effort to assess the constructability, performance, and applicability of bridges with fiber-reinforced polymer composite decks. This paper examines whether four common deck systems are able to realize many of the anticipated benefits of using FRP composites in lieu of conventional reinforced concrete bridge decks. Particular installation issues, connection details, and specific construction techniques for each deck system are described, along with a discussion of the shortcomings in terms of handling, performance, and serviceability. Other factors such as key design parameters (e.g., impact factor and thermal characteristics) and unexpected responses are used to further quantify the performance of four FRP representative deck systems under identical traffic and environmental constraints.     

Designing and Testing of Concrete Bridge Decks Reinforced with Glass FRP Bars

In addition to their high strength and light weight, fiber-reinforced polymer (FRP) composite reinforcing bars offer corrosion resistance, making them a promising alternative to traditional steel reinforcing bars in concrete bridge decks. FRP reinforcement has been used in several bridge decks recently constructed in North America. The Morristown Bridge, which is located in Vermont, United States, is a single span steel girder bridge with integral abutments spanning 43.90 m. The deck is a 230 mm thick concrete continuous slab over girders spaced at 2.36 m. The entire concrete deck slab was reinforced with glass FRP (GFRP) bars in two identical layers at the top and the bottom. The bridge is well instrumented at critical locations for internal temperature and strain data collection with fiber-optic sensors. The bridge was tested for service performance using standard truck loads. The construction procedure and field test results under actual service conditions revealed that GFRP rebar provides very good and promising performance.     

Critical Evaluation of Strain Measurements in Glass Fiber-Reinforced Polymer Bridge Decks

An experimental study of principal strains and deflections of glass fiber-reinforced polymer (GFRP) composite bridge deck systems is presented. The experimental results are shown to correlate well with those of an analytical model. While transverse strains and vertical deflections are observed to be consistent, repeatable, and predictable, longitudinal strains exhibit exceptional sensitivity to both strain sensor and applied load location. Large, reversing strain gradients are observed in the longitudinal direction of the bridge deck. GFRP deck system geometry, connectivity, material properties, and manufacturing imperfections coupled with the observed strains suggest that the performance of these structures should be assessed under fatigue loading conditions. Recommendations for accurately assessing longitudinal strain in GFRP bridge decks are made, and a review of existing data is suggested.     

Development of an Efficient Connector System for Fiber Reinforced Polymer Bridge Decks to Steel Girders

This paper discusses the development of an innovative and efficient connector to be used with fiber reinforced polymer (FRP) decks supported by steel girders. A summary is provided detailing various proprietary connectors currently employed by FRP deck manufacturers. The paper then describes the development and experimental testing of a clamped shear stud-type connector. Experimental testing was conducted in two phases. The first phase consisted of individual connector testing. In this phase, several variations of the connector are tested and evaluated for strength, damage development, and overall performance. Results of this phase of testing are used to select a final connection design to be used in the second phase of testing, which consisted of testing a scale model bridge that incorporates several of the proposed connectors. The bridge is subjected to static load tests and the resulting reactions and deflections from these tests are compared with comprehensive finite element models of the system.     

Fatigue and Strength Evaluation of Two Glass Fiber-Reinforced Polymer Bridge Decks

The use of glass fiber-reinforced polymer (GFRP) bridge decks is appealing for applications where minimizing dead load is critical. This paper describes fatigue and strength testing of two types of GFRP decks being considered for use in the retrofit of an aging steel arch bridge in Snohomish County, Washington, where a roadway expansion is necessary and it is desirable to minimize the improvements to the arch superstructure. Each test used a setup designed to be as close as practicable to what will be the in situ conditions for the deck, which included a 2% cross slope for drainage. The fatigue testing consisted of a single 116 kN (26 kip) load applied for 2 million cycles, which corresponds to an AASHTO HS-25 truck with a 30% impact factor, and the strength testing consisted of multiple runs of a monotonically applied minimum load of 347 kN (78 kips). Results from the fatigue testing indicated a degradation of the stiffness of both deck types; however, the degradation was limited to less than 12% over the duration of loading. Further, the results showed both deck types accumulated permanent deck displacement during fatigue loading and one deck type used a detail with poor fatigue performance. That detail detrimentally impacted the overall deck performance and caused large permanent deck deformations. It was also found that degradation of composite behavior between the deck and girders occurs during fatigue loading and should be included in design.     

Laboratory and Field Performance of Cellular Fiber-Reinforced Polymer Composite Bridge Deck Systems

This paper addresses the laboratory and field performance of multicellular fiber-reinforced polymer (FRP) composite bridge deck systems produced from adhesively bonded pultrusions. Two methods of deck contact loading were examined: a steel patch dimensioned according to the AASHTO Bridge Design Specifications, and a simulated tire patch constructed from an actual truck tire reinforced with silicon rubber. Under these conditions, deck stiffness, strength, and failure characteristics of the cellular FRP decks were examined. The simulated tire loading was shown to develop greater global deflections given the same static load. The failure mode is localized and dominated by transverse bending failure of the composites under the simulated tire loading as opposed to punching shear for the AASHTO recommended patch load. A field testing facility was designed and constructed in which FRP decks were installed, tested, and monitored to study the decks’ in-service field performance. No significant loss of deck capacity was observed after more than one year of field service. However, it was shown that unsupported edges (or free edges) are undesirable due to transitional stiffness from approach to the unsupported deck edge.     

Shear Strength of One-Way Concrete Slabs Reinforced with Fiber-Reinforced Polymer Composite Bars

This paper evaluates the shear strength of one-way concrete slabs reinforced with different types of fiber-reinforced polymer (FRP) bars. A total of eight full-size slabs were constructed and tested. The slabs were 3,100?mm?long×?1,000?mm?wide×200?mm?deep. The test parameters were the type and size of FRP reinforcing bars and the reinforcement ratio. Five slabs were reinforced with glass FRP and three were reinforced with carbon FRP bars. The slabs were tested under four-point bending over a simply supported clear span of 2,500 mm and a shear span of 1,000 mm. All the test slabs failed in shear before reaching the design flexural capacity. The experimental shear strengths were compared with some theoretical predictions, including the JSCE recommendations, the CAN/CSA-S806-02 code, and the ACI 440.1R-03 design guidelines. The results indicated that the ACI 440.1R-03 design method for predicting the concrete shear strength of FRP slabs is very conservative. Better predictions were obtained by both the CAN/CSA-S806-02 code and the JSCE design recommendations.     

Structural Characterization of Hybrid Fiber-Reinforced Polymer-Glulam Panels for Bridge Decks

The structural characterization of hybrid fiber-reinforced polymer (FRP)–glued laminated (glulam) panels for bridge deck construction is examined using a combined analytical and experimental approach. The structural system is based on the concept of sandwich construction with strong and stiff FRP composite skins bonded to an inner glulam panel. The FRP composite material was made of E-glass reinforcing fabrics embedded in a vinyl ester resin matrix. The glulam panels were fabricated with bonded eastern hemlock vertical laminations. The FRP reinforcement was applied on the top and bottom faces of the glulam panel by wet layup and compacted using vacuum bagging. An experimental protocol based on a two-span continuous bending test configuration is proposed to characterize the stiffness, ductility, and strength response of FRP-glulam panels under simulated loads. Half-scale FRP-glulam panel prototypes with two different fiber orientations, unidirectional (0°) and angle-ply (±45°), were studied and the structural response correlated with control glulam panels. A simple beam linear model based on laminate analysis and first-order shear deformation theory was proposed to compute stiffness properties and to predict service load deflections. In addition, a beam nonlinear model based on layered moment-curvature numerical analysis was proposed to predict ultimate load and deflections. Correlations between experimental results and the two proposed beam models emphasize the need for complementing both analytical tools to characterize the hybrid panel structural response with a view toward bridge deck design.     

Experimental Behavior of Carbon Fiber-Reinforced Polymer (CFRP) Sheets Attached to Concrete Surfaces Using CFRP Anchors

Fiber-reinforced polymer (FRP) composite sheets have gained popularity as a viable strengthening technique for existing reinforced concrete structures. The efficiency of the strengthening system largely depends on adequate bond between FRP sheets and the concrete substrate. In recent years, techniques to anchor FRP sheets have been proposed in applications that have limited distance to develop FRP sheet strength. One promising technique consists of fabricating and bonding FRP anchors during the FRP sheet saturation and embedding them into predrilled holes in the concrete substrate. This paper presents experimental results highlighting the complex behavior between FRP sheets and anchors. The primary failure modes that the sheet-anchor system can experience are identified. The experiments identify the main variables that influence the FRP anchor-sheet system behavior. This research contributes to the needed experimental database that will aid in future development of design recommendations of this anchorage system.     

Fiber-Reinforced Polymer Composites for Construction—State-of-the-Art Review

A concise state-of-the-art survey of fiber-reinforced polymer (also known as fiber-reinforced plastic) composites for construction applications in civil engineering is presented. The paper is organized into separate sections on structural shapes, bridge decks, internal reinforcements, externally bonded reinforcements, and standards and codes. Each section includes a historical review, the current state of the art, and future challenges.     

Barrier Wall Impact Simulation of Reinforced Concrete Decks with Steel and Glass Fiber Reinforced Polymer Bars

Many experimental studies have been performed to evaluate the behavior of noncorroding glass fiber reinforced polymer (GFRP) rebars in reinforced concrete (RC) flexural members. Relatively few studies have focused on the behavior of bridge deck overhangs in the event of a barrier wall impact, which subjects this region to a combination of flexure, shear, and axial tension. The objective of this investigation is to evaluate deck overhangs under these forces. Three bridge deck reinforcing schemes were considered in the study: all epoxy-coated steel (ECS), all GFRP, and hybrid made up of a top mat of GFRP rebars and a bottom mat of ECS rebars. Laboratory testing of nine RC specimens was performed. Results showed that all three reinforcing schemes meet the AASHTO requirements.     

Filament-Wound Glass Fiber Reinforced Polymer Bridge Deck Modules

The demand for the development of efficient and durable bridge decks is a priority for most of the highway authorities worldwide. This paper summarizes the results of an experimental program designed to study the behavior of an innovative glass fiber reinforced polymer (GFRP) bridge deck recently patented in Canada. The deck consisted of a number of triangular filament wound tubes bonded with epoxy resin. GFRP plates were adhered to the top and bottom of the tubes to create one modular unit. The experimental program, described in this paper, discusses the evolution of two generations of the bridge deck. In the first generation, three prototype specimens were tested to failure, and their performance was analyzed. Based on the behavior observed, a second generation of bridge decks was fabricated and tested. The performance was evaluated based on load capacity, mode of failure, deflection at service load level, and strain behavior. All decks tested exceeded the requirements to support HS30 design truck loads specified by AASHTO with a margin of safety. This paper also presents an analytical model, based on Classical Laminate Theory to predict the load-deflection behavior of the FRP decks up to service load level. In all cases the model predicted the deck behavior very well.     

Evaluation of Effective Width and Distribution Factors for GFRP Bridge Decks Supported on Steel Girders

Glass fiber-reinforced polymer (GFRP) bridge deck systems offer an attractive alternative to concrete decks, particularly for bridge rehabilitation projects. Current design practice treats GFRP deck systems in a manner similar to concrete decks, but the results of this study indicate that this approach may lead to nonconservative bridge girder designs. Results from a number of in situ load tests of three steel girder bridges having the same GFRP deck system are used to determine the degree of composite action that may be developed and the transverse distribution of wheel loads that may be assumed for such structures. Results from this work indicate that appropriately conservative design values may be found by assuming no composite action between a GFRP deck and steel girder and using the lever rule to determine transverse load distribution. Additionally, when used to replace an existing concrete deck, the lighter GFRP deck will likely result in lower total stresses in the supporting girders, although, due to the decreased effective width and increased distribution factors, the live-load-induced stress range is likely to be increased. Thus, existing fatigue-prone details may become a concern and require additional attention in design.     

Field Performance of the Fiber-Reinforced Polymer Deck of a Truss Bridge

The MD 24 Bridge over Deer Creek in Harford County, Md., was one of the projects chosen by the Federal Highway Administration’s Innovative Bridge Research and Construction Program for bridge deck replacement by fiber-reinforced polymer (FRP) composites. A thorough discussion is presented on Maryland State Highway Administration’s first bridge rehabilitation project utilizing a FRP deck. The discussion includes design details, installation procedure, construction methods and in situ load testing with a wireless monitoring system. The research team installed a monitoring system to record the effects of live loads on the bridge system, including truss members, steel stringers, and plate action of the FRP deck. Finite-element models were also used in this phase. Dynamic effects of the FRP system, composite action between steel stringers and the FRP deck as well as the effective width and distribution factors of stringers were obtained and compared with the AASHTO specifications. Recommendations are also offered on improving the design details based on this experience.     

Repair of Steel Composite Beams with Carbon Fiber-Reinforced Polymer Plates

One significant cause of deterioration of steel bridge structures is the corrosion due to extensive use of deicing salts in winter weather. The investigation presented in this paper focused on the behavior of steel composite beams damaged intentionally at their tension flange to simulate corrosion and then repaired with carbon fiber-reinforced polymer (CFRP) plates attached to their tension areas side. Damage to the beams was induced by removing part of the bottom flange, which was varied between no damage and loss of 75% of the bottom flange. All beams were tested to failure to observe their behavior in the elastic, inelastic, and ultimate states. To help implement this strengthening technique, a nonlinear analytical procedure was also developed to predict the behavior of the section/member in the elastic, inelastic, and ultimate states. The test results showed a significant increase in the strength and stiffness of the repaired beams. Through the use of CFRP plates, all damaged beams were fully restored to their original (undamaged state) strength.     

Composite Action and Adhesive Bond between Fiber-Reinforced Polymer Bridge Decks and Main Girders

This paper describes the behavior of hybrid girders consisting of fiber-reinforced polymer (FRP) bridge decks adhesively connected to steel main girders. Two large-scale girders were experimentally investigated at the serviceability and ultimate limit state as well as at failure. One of the girders was additionally fatigue loaded to 10 million cycles. Compared to the behavior of a reference steel girder, deflections of the two girders at the SLS were decreased by 30% and failure loads increased by 56% due to full composite action in the adhesive layer. A ductile failure mode occurred: Deck compression failure during yielding of the steel girder. The adhesive connections were able to prevent buckling of the yielding top steel flanges. Thus, compared to the reference steel girder, the maximum deflections at failure could be increased up to 130%. No deterioration due to fatigue loading was observed. Based on the experimental results, a conceptual design method for bonded FRP/steel girders was developed. The proposed method is based on the well-established design method for hybrid girders with concrete decks and shear stud connections. The necessary modifications are proposed.     

Use of Glass-Fiber-Reinforced Polymer Tendons for Stress-Laminating Timber Bridge Decks

Researchers at the University of Maine led an effort in the mid-1990s to develop and use glass-fiber-reinforced polymer (GFRP) tendons, instead of the commonly used steel-threaded bars, for stress-laminating timber bridge decks. The GFRP tendons are 12.7 mm (0.5 in.) in diameter and consist of seven-wire strands similar in construction to steel prestressing strands. Because the modulus of elasticity of the GFRP tendons is approximately 1/9 that of steel, they are not as susceptible to loss of prestress as steel bars and may not have to be restressed during the life of deck. In 1997, researchers obtained funding to design, construct, and monitor a stress-laminated timber bridge located in Milbridge, Maine, utilizing the new GFRP tendons. The bridge was constructed from preservative treated No. 2 and better eastern hemlock laminations and is 4.88 m (16 ft) long, 7.75 m (25 ft, 6 in.) wide, and 350 mm (14 in.) deep. Based on 4.25 years of field monitoring the tendon forces and moisture content, the GFRP tendons have maintained an adequate prestress level without having to be restressed.     

Strengthening of Eccentrically Loaded Reinforced Concrete Columns with Fiber-Reinforced Polymer Wrapping System: Experimental Investigation and Analytical Modeling

This paper presents the results of experimental program and analytical modeling for performance evaluation of a fiber-reinforced polymer (FRP) wrapping system to upgrade eccentrically loaded reinforced concrete (RC) columns. A total of 12 RC columns with end corbels were tested. The test specimen had an overall length of 1,200?mm. Each end corbel had a cross section of 250×250?mm and a length of 350?mm. The specimen in the test region was 125×125?mm having a longitudinal steel ratio of 1.9%. Test parameters included confinement condition (no wrapping, full FRP wrapping, and partial FRP wrapping), and eccentricity-to-section height (e/h) ratio (0.3, 0.43, 0.57, and 0.86). Research findings indicated that the strength gain caused by FRP wrapping decreased as e/h was increased. Full FRP wrapping resulted in about 37% enhancement in compression strength at a nominal e/h of 0.3, whereas only 3% strength gain was recorded at a nominal e/h of 0.86. The compression strengths of the partially wrapped columns were on average 5% lower than those of the fully wrapped columns. A nonlinear, second-order analysis that accounts for the change in eccentricity caused by the lateral deformation was proposed to predict the columns strength. A comparison between analytical and experimental results of the present study in addition to data published in the literature demonstrated the accuracy and validity of the proposed analysis.     

Characterization of a Low-Profile Fiber-Reinforced Polymer Deck System for Moveable Bridges

Moveable bridges in Florida typically use open steel grid decks due to weight limitations. However, these decks present rideability, environmental, and maintenance problems, as they are typically less skid resistant than a solid riding surface, create loud noises, and allow debris to fall through the grids. Replacing open steel grid decks with a lightweight fiber-reinforced polymer (FRP) deck can improve rideability and reduce maintenance costs, simultaneously satisfying the strict weight requirement for such bridges. In this investigation, a new low-profile, pultruded FRP deck system successfully passed the preliminary strength and fatigue tests per AASHTO requirements. Two two-span deck specimens were tested, one with the strong direction of the deck placed perpendicular to the supporting girders, whereas the other had a deck placed with 30° skew. This paper also describes a simplified finite-element approach that simulates the load–deformation behavior of the deck system. The results from the finite-element model showed a good correlation with the deflection and strain values measured from the tests.