glass fiber reinforced polymer(gfrp) rebar for …mohandes.com/resources/documents/gfrp.pdf ·...

Borna Hajimiragha

M.Eng , President and CEO at B&B FRP Manufacturing inc.

March 2016

Glass Fiber Reinforced Polymer(GFRP) Rebar

For Sustainable Infrastructure

Videos

1. Composite Rebar

2. GFRP reinforced Beam (OR)

3. GFRP reinforced Beam

2

https://www.youtube.com/watch?v=tCJSirTz9jA

https://www.youtube.com/watch?v=slQ8nPjNhIY&list=FLlYQTVZ5SdCVSJMTzrUNUJA&index=4

https://www.youtube.com/watch?v=slQ8nPjNhIY

OUTLINE

1. What justifies the use of MST-BAR™ in today's infrastructures?

2. How MST-BAR™ is manufactured

3. Main advantages of MST-BAR™

4. Codes, Designs & Standards

5. Mechanical & physical properties and durability of MST-BAR™

6. Cost Analysis

7. Structural behavior of Reinforced Concrete(RC) with different types

of rebar

3

WHY MST-BAR™ FOR TODAY INFRASTRUCTURES

4

Corrosion on bridge barrier walls

Corrosion on bridge decks &Utility poles

WHY CORROSION IS A PROBLEM?

Governments & Taxpayers can no longer afford to pay concurrently for replacing,

maintenance and expansion of infrastructure

Corrosion is draining the economy silently

Safety of infrastructures

Steel is an old material, it’s great but often does not fit some applications!

IS IT THEN JUSTIFIABLE TO BUILD AIRPLANES , SPACE SHUTTLES OR GAS-

STATION TANKS USING STEEL?!!!

5

MST-BAR™ Advantages Over Steel Rebar

CORROSION RESISTANCE - 100% resistance to any & all harsh environmental factors

BONDING STRENGTH - Much greater Bonding Strength to Concrete

Ease of Cutting - For TBM Application - Soft Eye

Fire rated- capacity to stand for more than 2 hours in direct fire with minimum concrete cover

Strength - 2 times stronger than steel with tensile strength of 1000MPa

Fatigue Strength - 20 times higher resistance under cyclic loading

Weight - 4 x lighter than steel (2100 Kg/m3 vs. 7800 Kg/m3)

Economical Curing - Concrete can be cured with sea water instead of clean water; economical

& recyclable

Conductivity - Electromagnetic non-conductive; for MRI Applications & other uses

Thermal non-conductivity - Makes it suitable for use in hot and cold environments

Detection by GPR - Easily detected by GPR

Thermal expansion - Very low thermal expansion factor results in added compatibility with

concrete

6

Codes, Designs & Standards

Substitution - Direct substitution of MST-BAR rebar with steel rebar may not be

possible in certain cases

Economy & Savings - Lower modulus of elasticity and shear strength have a direct

impact on the number of required reinforcing bars

Shear Strength – MST-BAR requires different factors and formula as per CSA and

ACI codes to be used as a shear reinforcement

See the following three slides for further information

MST-BAR™ - Mega Strength Bar

Tensile Strength (MPa) 1000

Loss of Tensile Strength

at -40C

0% Drop

Ultimate strain % 1.5 - 2%

Transverse Shear

Strength (MPa)

220

Elastic Modules (MPa) >60,000

Bond Strength to

Concrete (MPa)

>20

CURE RATIO % 100

Glass Transition

Temperature, C°

125

Density(Kg/m3) 2100

Part 1: Mechanical & Physical Properties of Straight GFRP

STEEL

450

It gets brittle

15%

300

190,000 to 200,000

>12

N/A

N/A

7800

Other GFRP Bars

550 - 800

Not tested

1-1.5%

150 MPa

40,000 to 60,000

>12

Poor cure ratio

1.5

2100

Canadian Standard Association (CSA)

CAN/CSA-S6-06 (2006) Fibre Reinforced Structures, “Canadian Highway Bridge Design Code”

Canadian Standards Association, pg.693-728

CAN/CSA-S806-02 (R2007) “Design and Construction of Building Components with Fibre-

Reinforced Polymers” Canadian Standards Association

The Structural Innovation & Monitoring Technologies Resource Centre (SIMTReC):

Manual No. 3 (Version 2) ”Reinforcing Concrete Structures with Fibre Reinforced Polymers

(FRPs)”, Dr. Sami Rizkalla, Dr. Aftab Mufti

Manual No. 4 “Strengthening Reinforced Concrete Structures with Externally-Bonded Fibre

Reinforced Polymers (FRPs)”, Dr. Kenneth Neale

Manual No. 5 ”Prestressing Concrete Structures with FRPs” Dr. Ivan Campbell

USA

ACI 440.1R-06 (2006) ”Report on Fiber Reinforced Poly. (FRP) Reinforcement for Concrete

Structures”, ACI Committee 440, American Concrete Institute

ACI 440R-07 (2007) ”Report on Fiber-Reinforced Polymer (FRP) Reinforcement for Concrete

Structures” ACI Committee 440, American Concrete Institute

ACI 440.5-08 (2008) ”Specification for Construction with Fiber-Reinforced Polymer Reinforcing

Bar” ACI Committee 440, American Concrete Institute

ACI 440.6-08 (2008) “Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials

for Concrete Reinforcement,” ACI Committee 440, American Concrete Institute

AASHTO GFRP-1 (2009) ” AASHTO LRFD Bridge Design Guide Specifications for GFRP-

Reinforced Concrete Bridge Decks and Traffic Railings”, American Association of State Highway

and Transportation Officials

Standard & Approvals

American Concrete Institution (ACI-440.3)

Canadian Standard Association (CSA-S807)

ISO 9001:2008 Quality Control BSI-British Standard Institution

Stress-Strain Curves

Stress Vs Strain Chart:Steel’s maximum stress level is 500MPa and GFRP is above 1000MPa for the same diameter.That is twice the load capacity of steel.

Actual Test Curve of MST-BAR for 16mm diameter bar

Comparison of MST-BAR with Steel and Carbon bar

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

100 1,000 10,000 100,000 1,000,000

No. of Cycles (Nos.)

Cra

ck

Wid

th (

mm

)

Comparison of GFRP, CFRP and STEEL

Reinforced Slabs

Cycles toFailure @ 60 t

23,162

198,863Cycles

420,684Cycles

Failure @ 60 t

23,162Cycles

STEEL

Punching Shear Failure Mode

STEELSTEEL

CFRP

GFRP

Fatigue under 60 t Load Fatigue under 60 t Load Punching Shear Failure Mode

STEEL

GFRP

CFRP

Fatigue Comparison GFRP/CFRP/STEEL

MST-BAR™: Completed Test Part A. Physical Properties

All The Tests are Completed in University Of Sherbrooke Under Supervision of Dr. Brahim Benmokrane

Prof. Dr. Brahim Benmokrane

• P. Eng., FRSC, FACI, FCSCE, FIIFC, FEIC, FCAE

• Professor of Civil Engineering

• Fellow of the Royal Society of Canada (Academy of Science)

• Canada Research Chair in Advanced Composite Materials for Civil Structures

• NSERC Research Chair in FRP Reinforcement for Concrete Infrastructure

• Director of the Quebec-FRQNT Research Center on Concrete Infrastructure ( CRIB)

• Director of the University of Sherbrooke Research Center on FRP Composite

• Materials for Structures (CRUSMaC)

MST-BAR™: Completed Test Part B. Mechanical Properties

Tensile properties at Ambient Temperature

Tensile Properties at -40°C

Durability test in Alkali Environment at

60°C, PH level 13 for 90 days

Bond Strength (Pullout)

Transverse Shear Strength

Creep Rupture and Strength

Bent Bar Tests

MST-BAR™: Typical Preparation for Mechanical Testing

Typical preparation of MST-BAR™ for tensile test. In order to achieve the exact load capacity of MST-BAR™ and avoid any premature failure of the bar due to compression at the clamp, the two ends of the bar are anchored to a heavy duty pipe with a special grout to add grip on Universal Tensile Test machine grips.


Typical package of MST-BAR ™ for CSA & ACI tests. All MST-BAR ™ were shipped to University of Sherbrooke to be tested.


Preparation of MST-BAR ™ for Alkali resistance under load. The test was carried out in an environmental chamber with a 60C temperature.The white tubes are filled with a high alkali mixture with a pH level of 13 , under 3000 micro strains load for 90 days.

Typical Preparation for Creep Test

Preparation of MST-BAR ™ for Creep and Creep Rupture tests.The bars were placed under a constant load for a period of ONE full year andthe strain in the material was measured in order to determine the maximum loadunder which the bar might remain unaffected for 113 years.

Figure 1: LVDT & Test Setup Figure 2: Typical Failure of MST-BAR

Tensile Strength >1000MPa

Typical Failure of MST-BAR in Tensile Test

Test Setup in -40C°, Failure of bar beyond the 1000MPa

NO REDUCTION IN STRENGTH

MST-BAR™ - Tensile Properties of 20mm Bar at -40°C Temperature

MST-BAR™ - Bar 15mm - Durability test at 60°C, pH Level of 13 for

90 Days(2160h)

After the bars have beenRemoved from alkali bath, Sodium, Calcium and Magnesium sediments are observed on the surface of the bars.

MST-BAR™ - Bar 15mm - Durability test at 60°C, pH Level of 13 for

90 Days

MST-BAR ™ in Alkali resistance under load for 2160h, at 60C temperatureWith a pH level of 13:

IT WILL RETAIN OVER 90% OF ITS ORIGINAL STRENGTH.

Transverse Shear Strength Test

Shear Test Setup

TRANSVERSE SHEAR STRENGRTH

BEYOND 220MPa IS MAINTAINED.

MST-BAR™ - Bond Strength

MTO & CSA Requirementsare only 8MPa

ALL MST-BAR BOND STRENGTHS WERE FOUND TO BE

BEYOND 20MPa

Bond Strength/Pull-OUT Test

Typical Pull-out test/bond Strength with concrete, In Excess of 100 tests were completed in order to determine the pull-out

capacity of the MST-BAR.

MST-BAR™ - Bond Strength

Graph below shows the slippage of the bar in concrete. The average bond strength for MST-BAR is above 20MPa with less than half mm

slippage.

MST-BAR ™ 10MM Under Creep Test

Creep test set-up to apply constant load on the bars.

Creep Rupture & Creep in Bar #3 (10mm)

Chart below clearly illustrate and shows that MST-BAR can continuously be in service for Log6(h) or 113 years , when it is

subjected to 49% of it’s capacity(500MPa).

Commercial Applications

MANY SUCCESSFUL PROJECTS COMPLETED

Water Treatment Plants Chemical Plants

Parking Garages Bridges

Case 1: STEEL Vs. GFRP

“Fibre reinforced polymer composite bars for the structural concrete slabs of a Public Works and Government Services Canada parking garage Brahim Benmokrane, Ehab El-Salakawy, Zoubir Cherrak, and Allan Wiseman NRC CANADA 2004”

Result Summary


Crack Details


Crack Pattern at Failure


COST SAVINGS OF MST-BAR™

TRANSPORTATION COSTS - 4 times lower due to its 73% lighter weight

Minimum required concrete cover - 38mm for bars #2 - 5 and 50mm for bars #6 - 8, the

regular steel bar concrete requires 65mm

Increased installer performance & less fatigue due to lighter weight - faster/cheaper

installation

MST-BAR® price with its proven higher performance will not add any extra cost to the

project how ever it will result in saving.

No water proofing membrane - a unique cost-saving feature

NEVER Epoxy-coat/paint/re-patch the concrete or replace the rusted bars - MST-BAR does

not required any maintenance

CONCLUSION: MST-BAR® with its proven higher performance not only will not add additional costs to the project; it will

certainly result in major savings

Cost Study: BLACK STEEL

Chloride ions, moisture and salts will penetrate through the membrane and begin corroding its top

reinforcement

CONCLUSION: 25 years after the road construction, its asphalt surface will have to be rehabilitated, the

membrane would require replacement and the upper reinforcement would corrode needing to be

replaced. Considering the life span of MST-BAR® at well over 100 years, the savings that it brings to

any and all construction projects is undoubtedly substantial

STUDY ON COST : DIFFERENT REINFORCEMENET

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

0 YEARS 25 YEARS 50 YEARS 75 YEARS 100 YEARS 150 YEARS

MST-BAR Stainless-Steel Epoxy-coated Black Steel

MST-BAR cost at 75 years is associated to Asphalt repair and concrete repair only and has nothing to do with reinforcement bar.

Ref: Demonstrating the Economical Benefit of GFRP bars in Deck . CDCC2007(Confrence on Durability of FRP Composite for Construction

Description Quantity $/Unit Total

Form Work 2800 m2 120 $/m2 $ 336,000.00

Rebar & Installation

50,000 Kg 2.5 $/kg $ 125,000.00

Concrete(30MPa) & Installation

t=254mm Area=2800Volume=711m3

250 $/m3 $ 177,800.00

Blast Track 2800 m2 3.25 $/m2 $ 9,100.00

Water Proofing(Double System)

2800 m2 35 $/m2 $ 98,000.00

Over Burden Asphalt 2800m2

Gravel 2800m227 $/m2

11 $/m2

$ 106,400.00

TOTAL $ 852,300.00

2800m2 - Roof Slab Steel-Reinforced Deck-Initial Cost


Form Work 2800 m2 120 $/m2 $ 336,000.00


50,000 Kg 3 $/kg $ 150,000.00



250 $/m3 $ 177,800.00

Blast Track 2800 m2 3.25 $/m2 $ 9,100.00

Water Proofing(Double System)

2800 m2 35 $/m2 $ 98,000.00



11 $/m2

$ 106,400.00

TOTAL $ 877,300.00

2800m2 - Roof Slab Epoxy Coated Rebar-Reinforced Deck-Initial Cost


Form Work 2800 m2 120 $/m2 $ 336,000.00


42,160m 3-6 $/m $ 211,000.00



250 $/m3 $ 140,000.00

Blast Track 2800 m2 3.25 $/m2 $ 9,100.00

Water Proofing(SingleSystem)

2800 m2 20 $/m2 $ 56,000.00

Over Burden Asphalt 2800m2 27 $/m2 $ 75,600.00

TOTAL $ 827,700.00

2800m2 - Roof Slab GFRP Rebar-Reinforced Deck-Initial Cost

Black Steel-Reinforced Deck-Initial Cost

$ 852,300.00

Epoxy Coated Rebar-Reinforced Deck-Initial Cost

$ 877,300.00

GFRP Reinforced- Deck-Initial Cost$ 827,700.00

3 Options- 2800m2 Parking DeckIt should be noted that the life expectancy of structured reinforced with MST-BAR is 150 years


Concretedemolition

980 m2 125 $/m2 $ 122,500.00


5,000 KgONLY 20% TOP

2.5 $/kg $ 12,500.00


t=101mm Area=980 m2

Volume=100 m3

250 $/m3 $ 25,000.00

Blast Track 2800 m2 3.25 $/m2 $ 9,100.00

Water Proofing(DoubleSystem)(RE&RE)

2800 m2 35 $/m2

REM. 6 $/m2

$ 114,800.00



11 $/m2

$ 182,000.00

TOTAL $ 465,830.00

REPAIR !!!2800m2 –Roof Slab Steel-Reinforced Deck-35%(ONLY TOP SLABCONSIDERED, NO THROUGH SLAB OR UNDER SIDE REPAIR)4’’(101MM) TOP SLAB25 TO 30 YEARS REPAIR ,CONSIDERING 0% INFLATION!!!

RE&RE:REMOVAL & REPLEACMENET

BLACK Steel


Concretedemolition

980 m2 125 $/m2 $ 122,500.00


5,000 KgONLY 20% TOP

3 $/kg $ 15,000.00


t=101mm Area=980 m2

Volume=100 m3

250 $/m3 $ 25,000.00

Blast Track 2800 m2 3.25 $/m2 $ 9,100.00


2800 m2 35 $/m2

REM. 6 $/m2

$ 114,800.00



11 $/m2

$ 182,000.00

TOTAL $ 468,330.00

REPAIR!!!2800m2 –Roof Slab Epoxy coated-Reinforced Deck-35%(ONLY TOP SLABCONSIDERED, NO THROUGH SLAB OR UNDER SIDE REPAIR)4’’(101MM) TOP SLAB25 TO 30 YEARS REPAIR ,CONSIDERING 0% INFLATION!!!


Epoxy Coated Steel


Concretedemolition

0 0 $/m2 $ 0


0 0 $/kg $ 0


0 0 $/m3 $ 0

Blast Track 0 0 $/m2 $ 0


35 $/m2

REM. 6 $/m2

$ 0


Optional54 $/m2 $ 151,200.00

TOTAL $ 151,200.00

NO REPAIR Required!!!2800m2 –Roof Slab Epoxy coated-Reinforced Deck-35%(ONLY TOP SLABCONSIDERED)4’’(101MM) TOP SLAB25 TO 30 YEARS REPAIR ,CONSIDERIN 0% INFLATION!!!


MST-BAR

Black Steel-Reinforced Deck-Initial Cost

$ 1,318,130.00

Epoxy Coated Rebar-Reinforced Deck-Initial Cost

$ 1,345,630.00

MST-BAR GFRP Reinforced- Deck-Initial Cost

$ 827,700.00

Cost of 2800m2 Parking Deck After 25 - 30 years

It should be noted that the life expectancy of structured reinforced with MST-BAR is 150 years

glass fiber reinforced polymer(gfrp) rebar for …mohandes.com/resources/documents/gfrp.pdf ·...

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