Innovative Use Of FRP For Sustainable Precast Concrete Structures. Sami Rizkalla Distinguished Professor North Carolina State University, USA
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1 Innovative Use Of FRP For Sustainable Precast Concrete Structures Sami Rizkalla Distinguished Professor North Carolina State University, USA
2 FRP MATERIALS Fibers: GFRP CFRP AFRP + Resins: Epoxy Polyester Fiber Reinforced Polymers: Bars, Tendons, Grids, Laminates
3 FRP MATERIALS High strength toweight ratio Excellent durability Non magnetic Low transversal resistance (temporary works) Stress (ksi) HM CFRP (pitch) (220 ksi) CFRP (pan) (310 ksi) AFRP (240 ksi) GFRP (180 ksi) Steel (60 ksi) 0 0% 1% 2% 3% 4% 5% Strain
4 FRP MATERIALS FRP Fiber Reinforced Polymer Fiber Polymer Matrix
5 SEM IMAGE: CARBON/EPOXY
6 Earlier Applications Bridge Girders Concrete Filled Precast Piles Utility Poles
7 Earlier Applications Bridge Girders Concrete Filled Precast Piles Utility Poles
8 1993 Beddington Trail Bridge First Bulb-Tee bridge girder pre-tensioned with CFRP tendons, and monitored using Fiber Optic Sensors
9 1993 Beddington Trail Bridge No signs of degradation when tested in July 2008, after 15 years of service
10 1997 Taylor Bridge Instrumentation of the girder before casting First AASHTO Girder prestressed with CFRP tendons CFRP stirrups and deck reinforcement GFRP reinforced barrier walls Monitored using Fiber Optic Sensors
11 1998 PCI Innovative Design Award
12 Earlier Applications Bridge Girders Concrete Filled Precast Piles Utility Poles
13 Concrete Filled Precast Piles 700 load (kn) Confinement effect + Bending Resistance strain ( ) Axial Resistance
14 Route 40 Bridge, Virginia
15 Earlier Applications Bridge Girders Concrete Filled Precast Piles Utility Poles
16 Power line poles 5.8 t 12 t
17 Power line poles
18 Recent Advances In Precast Double-Tee beams Wall Panels Composite Non-composite Architectural Cladding
19 Recent Advances in Precast Double-Tee beams Wall Panels Composite Non-composite Architectural Cladding
20 Double Tee s in Parking Structures
21 Corrosion Free Double Tee Thin flange susceptible to chloride penetration CFRP Grid replacement for WWF conventional steel
22 Carbon Fiber Grids Carbon grids are manufactured in an automated process: High production volume High quality control
23 Pre topped Double Tees 23
24 Pre topped Double Tees 24
25 Carbon Fiber Installation Embedment and finishing machine to place the grid More precisely for optimum performance More consistent; less opportunity for human error
26 Research and Development at NCSU Flanges reinforced with CFRP grid Uniformly distributed applied load
27 Experimental Program
28 Testing Program
29 Testing Program Initial Cracking: DT1 DT2
30 Failure Mode DT1 2 thick flange Test Results
31 Failure Mode DT1 2 thick flange Test Results
32 Concentrated Load Test Failure load = 11,300 lbs
33 Connected DT
34 Field Testing (3) blocks = 16k on each side of the DT pair. Each block 24 x38 x72 Support blocks
35 Test Setup
36 Test Setup
37 Mid span Between Connectors
38 Midspan Between Connectors
39 Mid span Between Connectors Spanning the Gap
40 Recent Testing under Uniform pressure
41 Double Tee
42 Double Tee
43
44
45
46 Carbon Fiber Rupture
47 Recent Advances in Precast Double-Tee beams Wall Panels Composite Non-composite Architectural Cladding
48 Prestressed Concrete Sandwich Load Bearing Panels Resist vertical and lateral loads Provide building envelope Consists of two concrete wythes and a layer of rigid foam. Composite action achieved by shear connectors
49 Typical Wythe Connectors Steel truss connectors Thermally inefficient, Structurally efficient Steel tie connectors Thermally and structurally inefficient Discrete GFRP connectors Structurally inefficient, Thermally efficient Concrete solid zones Thermally inefficient
50 Composite Action Fully Composite Structurally efficient Thinner, lighter panels possible Non Composite Structurally inefficient Each wythe resists applied moment independently Partially Composite Capacity falls between full and non composite panels
51 GFRP Shear Grid Orthogonal FRP Grid Cut at a 45-degree angle to develop a truss action Provides composite action Structurally and thermally efficient 51
52 Insulated Sandwich Panel Wythe Reinforcement Exterior Interior Pilaster Carbon Fiber Shear Connector Typical Cross Section Carbon fiber grid shear connectors provide composite action between wythes; and 52 increase insulation value due to low thermal conductivity of the connector.
53 Experimental Program
54 Overall Panel Behavior Lateral Deflection (cm) Composite Lateral Load (lbs) Ultimate Load Representative EPS Panel Lateral Load (kn) 5000 Service Load 22 Non-composite Lateral Deflection (in)
55 Degree of Shear Connection
56 Experimental Results EPS 2 1.2D+0.5L r +1.6W 150
57 Flexural shear failure Failure Modes
58 Panel Separation Failure Modes
59 42 ft Sandwich Panel
60 42 foot panel tests
61 Strains on Panel Edge at Midspan
62 Typical Precast Concrete Sandwich Panel 3 Wythe Panel
63 Push out Specimens Testing Frame Data Acquisition System Load Cell 60 ton Hydraulic Jack Hydraulic Pump 2 Steel Bar, Supporting Outer Wythes
64 Experimental Program to study the effect of the various parameters Insulation Type High Density EPS (32 kg/m 3 ) Sandblasted XPS Untreated XPS Grid Spacing 300 mm 600 mm Insulation Thickness 50 mm 100 mm 150 mm HD EPS only Bond of the Rigid Foam Push Out Specimens with no GFRP Grid Grid Type High Strength : 10mm strand at 35mm spacing Normal Strength : 10mm strand at 53mm spacing CGRID Aging Effect (Freeze Thaw) 4 Specimens with 29 ºC to 60 ºC Freeze Thaw Cycles
65 Typical Failure Modes EPS Typ. Buckling of Cords in Compression XPS *No Pull Out Observed
66 Long Term Behavior
67 Thermal Cycles Chamber Panel Temperature (ºC) Temperature (ºF) Time (Days) Thermal Cycles -40 Environmental Chamber for Freeze-Thaw Cycles
68 Proposed Shear Flow Design Equation
69 Accuracy of the proposed Equation Avg. Experimental Shear Flow (kn/m) HD EPS XPS SB XPS 0 1 kn/m = 5.7 lb/in Avg. Calculated Shear Flow (kn/m)
70 Recent Advances in Precast Double Tee beams Wall Panels Composite Non composite Architectural Cladding
71 Recent Advances in Precast Double Tee beams Wall Panels Composite Non composite Architectural Cladding
72 Insulated Architectural Cladding Steel reinforced precast rib CFRP shear grid (thermal break) Insulating Foam CFRP grid secondary reinforcing Thin brick finish
73 Manufacturing Process
74 Test Setup At NCSU
75 Full-Scale Experimental Validation ± 1.2 kpa cyclic loading 2.5 kpa static loading
76 Specimen after Sustaining Factored Load in Both Directions (No Cracks)
77 Final Crack Pattern
78 Pressure vs. Deflection
79 Failure due to Pullout of End Connections
80 ProLogis Distribution Warehouse LOCATION: South Brunswick, N.J. ARCHITECT: Arco Design Build, Conshohocken, Pa. SIZE: 751,000 sq. ft.
81 Proximity Hotel LOCATION: Greensboro, NC ARCHITECT: Centrepoint Architecture SIZE: 118,000 sq. ft. SURFACE AREA: 55,000 sq. ft. AWARDS: LEED Platinum, USGBC GreenSite Project of the Year, 2010
82 Under Development Precast Prestressed Concrete Piles
83 Impact Force Steel Spirals Corrosion Replacement CFRP Grid
84 Testing of Pile Specimens
85 Prestressing and CGRID for Confinement
86 Casting with SSC
87 Testing by FDOT
88 Testing by FDOT
89 Closing Remarks Innovative use of FRP will lead to significant advancements in design, construction and sustainability of precast concrete structures and bridges. Questions?
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