HYBRID FIBER REINFORCED POLYMER (FRP) SYSTEM OF CARBON FRP LAMINATE AND SPRAYED GLASS FRP FOR STRENGTHENING REINFORCED CONCRETE BEAMS By NINGFENG LIANG A DISSERTATION PRESENTED TO THE GRADUATE SCHOOL OF THE UNIVERSITY OF FLORIDA IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF DOCTOR OF PHILOSOPHY UNIVERSITY OF FLORIDA 2006 UMI Number: 3228772 UMI Microform 3228772 Copyright 2007 by ProQuest Information and Learning Company All rights reserved This microform edition is protected against unauthorized copying under Title 17, United States Code ProQuest Information and Learning Company 300 North Zeeb Road P.O Box 1346 Ann Arbor, MI 48106-1346 Copyright 2006 by NINGFENG LIANG To my parents and Hong ACKNOWLEDGMENTS First, I would like to thank Dr Andrew Boyd, my advisor, for his constant support and guidance in the entire course of this research The assistance by all the other committee members to form the research content is truly appreciated as well Second, without the collaboration with those lab and department staffs, it would be impossible for this research to be finished Specifically, my sincere thanks go to JJ, Chuck, Danny, George and Tony I really enjoyed working with all of them Third, I really appreciate the generous donation of the CFRP laminates by Sika Ron made sure the materials arrived on time and in good shape The same appreciation also goes to MVP for donating the spraying equipment, resin and glass fiber Gregg provided invaluable technical assistance in operating the spraying equipment Last, but not least, the friendship shown by Yanjun, Huamin, Xiaoyan, Yu Chen and Jeff will keep me cherishing the time I spent at the University of Florida for the rest of my life Their encouragement and help made the days of hard work enjoyable iv TABLE OF CONTENTS page ACKNOWLEDGMENTS iv LIST OF TABLES viii LIST OF FIGURES ix LIST OF ACRONYMS xii ABSTRACT xiii CHAPTER INTRODUCTION General Research Objectives Thesis Structure LITERATURE REVIEW .6 FRP Materials .6 Bond Strength of FRP-concrete Joint Flexural Strengthening of RC Beams 12 Brief History 12 Failure Modes 15 Flexural Strength Models 18 Shear Strengthening of RC Beams .20 Introduction 20 Failure Modes 23 Shear Strength Models 23 Sprayed FRP .24 Design Guideline 26 Flexural Strengthening 26 Shear Strengthening 28 MATERIAL PROPERTIES .30 Preparation of Sprayed FRP .31 v Component Materials 31 Spraying Equipment 32 Spraying Process 34 Effects of Specimen Orientation and Thickness .36 Specimen Preparation and Testing Setup 36 Results and Discussion 39 Effects of Fiber Length .39 Specimen Preparation 39 Results and Discussion 40 Effects of Fiber Content 43 Specimen Preparation 43 Results and Discussion 43 Concrete 44 Steel 45 Carbon Fiber Reinforced Polymer (CFRP) Laminate 45 BEAM STRENGTHENING WITH CFRP/SPRAYED GFRP HYBRID SYSTEM.48 Introduction .48 Preparation of Reinforced Concrete Beams .48 Beam Formwork 48 Beam Casting .49 Beam Testing Program .51 Concrete Beam Design 51 Strengthening Plan .52 Program Objectives .53 Strengthening Details 54 Simulated Steel Corrosion 56 FRP Strengthening of Beams 58 Load Test 62 Test Setup and Procedure 62 Instrumentation 64 Results and Discussion .66 Failure Modes 70 Energy Absorption .76 Beam Deflection Profile 79 Steel Strain 83 CFRP Strains .85 Sprayed GFRP Strains .87 Effects of Reinforcement 89 THEORETICAL ANALYSIS 91 Classical Beam Analysis 91 Material Models 92 Moment-Curvature Analysis .94 Calculation of Mid-span Deflection 101 vi Finite Element Analysis 102 Results and Discussion .104 Load and Deflection 104 Material Strains 110 Steel strains 111 CFRP strains .115 Sprayed GFRP strains 117 DESIGN GUIDELINES 123 Notation 124 Design Procedure 126 Design Example 128 REPAIR OF A CONCRETE BRIDGE WITH CFRP/SPRAYED GFRP HYBRID SYSTEM 133 Introduction .133 Background .133 Bridge Conditions Before Repair .135 Strengthening Design 137 Load Test before Repair 137 Materials 138 Flexural Strength .138 Shear Strength 139 Installation of CFRP-sprayed GFRP System 141 Environmental Issues and Protection 141 Repair Work 144 CONCLUSIONS AND RECOMMENDATIONS 151 APPENDIX MATHCAD PROGRAM FOR THE CLASSICAL BEAM ANALYSIS .154 LIST OF REFERENCES .165 BIOGRAPHICAL SKETCH 173 vii LIST OF TABLES page Table 2-1 Typical tensile properties of fibers used in FRP systems 2-2 Typical mechanical properties of GFRP, CFRP and AFRP composites 3-1 Material properties of resin .31 3-2 Material properties of glass fiber 32 3-3 Typical laminate mechanical properties (Ortho polyester) 32 3-4 Effect of specimen orientation 39 3-5 Effect of sprayed FRP thickness .39 3-6 Effect of fiber length on material properties of sprayed FRP 40 3-7 Effects of fiber content on material properties of sprayed FRP 43 3-8.Tensile properties of reinforcing steel 45 3-9 Properties of CFRP 46 4-1 Beam configuration .52 4-2 Summary of beam test results 67 5-1 Theoretical beam results 105 6-1 Design nominal load-carrying capacity of strengthened beams 132 7-1 Materials properties-bridge repair 138 7-2 Nominal strength of bridge girders 141 viii LIST OF FIGURES page Figure 1-1 Typical flexural strengthening scheme for RC beams with FRP laminate 2-1 Bond test 10 2-2 A Typical flexural strengthening scheme for a RC beam with FRP laminate 12 2-3 Failure modes of beams FRP strengthened in flexure 16 2-4 Shear strengthening 20 3-1 Spraying equipment 33 3-2 Geometry of testing specimen .36 3-3 Specimen layout on sprayed FRP panel 37 3-4 Sprayed FRP tensile test setup 38 3-5 Typical stress-strain curve from sprayed FRP tensile test 38 3-6 Effects of fiber length 41 4-1 Partial assembly of a beam form 49 4-2 Beam casting site layout 50 4-3 Concrete truck delivering concrete to wooden forms .51 4-4 Concrete beam details .52 4-5 Beam strengthening schemes 55 4-6 Simulated damages 57 4-7 Sandblasting concrete beam surfaces 58 4-8 Setup for CFRP laminate bonding 59 4-9 Application of sprayed GFRP .61 ix 159 ( limts( c) := if d cr( c) < d ts , d ts , limtemp( c) ⌠ Fcts ( c) := ⎮ ⌡ ) h b ( z) fc( c , z) dz ⌠ M cts ( c) := ⎮ ⌡ limts( c) h ( c − z)b ( z) fc( c , z) dz limts( c) Compute Strain in CFRP εcfrp( c) := if⎛⎜ cfrp ⎝ "True" , c−h c ⋅ εcm( c) , 0⎞ εcfrp( 2.5in) = × 10 ⎠ Compute Force and Moment in CFRP Fcfrp( c) := Ecfrp⋅ εcfrp( c) ⋅ A cfrp M cfrp( c) := Fcfrp( c) ( c − h ) Compute Strain in SGFRP εsgfrp ( c , z) := if⎛⎜ sgfrp "True" , ⎝ c−z c ⋅ εcm( c) , 0⎞ ⎠ Compute Force in SGFRP ⌠ Fsgfrp ( c) := tsgfrp ⋅ ⎮ ⌡ h Esgfrp ⋅ εsgfrp ( c , z) dz 0in h ⌠ M sgfrp ( c) := tsgfrp ⋅ ⎮ ⌡ Esgfrp ⋅ εsgfrp ( c , z) ⋅ ( c − z) dz 0in Total Section Force and Solution of Root P( c) := Fcc ( c) + Fct ( c) + Fcts ( c) + Fss ( c) + Fcfrp( c) + Fsgfrp ( c) 160 Print concret and steel forces for numerous trial neutral axis depths This was used to help locate "bugs" in the calculation procedure, during development and use of the worksheet c := 0.5in , 3in h Fcc ( c) = 25.71?0 Fct ( c) = lbf Fss ( c) = Fcts ( c) = -72.24?0 lbf -7.014?0 lbf -28.601?0 154.259?0 -433.441?0 -15.696?0 -90.633?0 282.808?0 -794.641?0 -21.116?0 -76.766?0 411.357?0 -1.156?0 -26.393?0 -68.897?0 539.906?0 -1.517?0 -30.419?0 -31.478?0 668.455?0 -1.878?0 -21.668?0 895.511?0 797.004?0 -2.239?0 -10.466?0 22.468?0 925.553?0 0?0 0?0 34.895?0 Fs ( c , 0) = -28.697?0 Fs ( c , 1) = lbf 95.405?0 Fcfrp( c) = lbf 0?0 lbf Fsgfrp ( c) = lbf 0?0 8.626?0 -99.259?0 0?0 0?0 17.475?0 -94.242?0 0?0 0?0 21.386?0 -90.283?0 0?0 0?0 23.491?0 -54.97?0 0?0 0?0 24.79?0 -23.895?0 0?0 0?0 25.235?0 -2.768?0 0?0 0?0 25.306?0 9.588?0 0?0 0?0 P( c) = -9.978?0 47.496?0 184.132?0 314.911?0 476.492?0 645.804?0 806.766?0 960.448?0 lbf lbf 161 Check Section Equilibrium c := 3in cc := root ( P( c) , c) cc = 2.226 × 10 in Fcc ( cc ) = 114.484× 10 lbf Fs ( cc , 0) = 2.603 × 10 lbf (cc = Neutral Axis Depth for Equilibrium) Fs ( cc , 1) = −103.067× 10 lbf − 12 Fsgfrp ( cc ) = × 10 lbf Fcts ( cc ) = −13.699× 10 lbf Fct ( cc ) = −321.681× 10 lbf P( cc ) = 231.571× 10 Fcfrp( cc ) = × 10 lbf lbf Results φ := εcm( cc ) M := M cc ( cc ) + M ct ( cc ) + M cts ( cc ) + M ss ( cc ) + M cfrp( c) + M sgfrp ( c) cc −3 φ = 1.572 × 10 M = 1.725 × 10 lbf ⋅ in in −3 εs ( cc , 1) = −21.652× 10 εcfrp( cc ) −εcfrpu = × 10 cc = 2.226 × 10 in εcfrp( cc ) = × 10 OK εsgfrp ( cc , h ) −εsgfrpu −3 εcm( cc ) = 3.5 × 10 εsgfrp ( cc , h ) = × 10 = × 10 OK 162 Matrices of Results of All Runs ⎛ 1689 ⎜ 1705 ⎜ MΦay := ⎜ 1718 ⎜ 1725 ⎜ ⎝ 1725 ⎛ ⎜ ⎜ 83.51 ⎜ 167.019 ⎜ 250.5 ⎜ ⎜ 334 ⎜ 417.5 ⎜ 732.5 ⎜ ⎜ 786.5 ⎜ 878.6 MΦby := ⎜ ⎜ 984 ⎜ 1096 ⎜ 1212 ⎜ ⎜ 1332 ⎜ 1452 ⎜ 1575 ⎜ ⎜ 1654 ⎜ 1678 ⎜ ⎝ 1689 731.8 ⎞ 994.6 ⎟ 1228 ⎟ 1418 ⎟ 1572 ⎠ ( ) MΦby := csort MΦby , ( ( ) vs := pwrfit( M by , Φ by , vg ) fby ( x) := interp ( vs , M by , Φ by , x) ) M by := submatrix MΦby , , rows MΦby − , , vs fby ( x) := vs ⋅ x 0 ⎞ 3.2 ⎟ ⎟ 9.5 ⎟ ⎟ 12.7 ⎟ 15.9 ⎟ ⎟ 47.1 ⎟ 70.7 ⎟ 94.6 ⎟ ⎟ 118.6 ⎟ 142.7 ⎟ 166.8 ⎟ ⎟ 191 ⎟ 215.4 ⎟ ⎟ 239.7 ⎟ 255.4 ⎟ 474.2 ⎟ 6.3 731.8 ⎠ ⎛1⎞ vg := ⎜ ⎜ ⎝0⎠ ( ( ) ⎛ 1.035 × 10 ⎜ vs = ⎜ 2.674 × 100 ⎟ ⎜ ⎟ ⎜ −2.067 × 100 ⎝ ⎠ −6⎞ 2000 fby ( x)1000 Curvature-moment curve before steel yielding 1000 x 2000 ) Φ by := submatrix MΦby , , rows MΦby − , , 163 ( ) MΦay := csort MΦay , ( ( ) ) M ay := submatrix MΦay , , rows MΦay − , , ( vs := pwrfit M ay , Φ ay , vg ) ( ) fay ( x) := interp vs , M ay , Φ ay , x vs1 fay ( x) := vs ⋅ x + vs ( ( ) ) Φ ay := submatrix MΦay , , rows MΦay − , , ⎛ 3.014 × 100 ⎞ ⎜ vs = ⎜ 1.233 × 100 ⎟ ⎟ ⎜ ⎜ ⎝ −28.126× 10 ⎠ 2000 fay ( x)1000 Curvature-moment curve after steel yielding 1000 2000 x Calculate the Mid-span Deflection Input Parameters L := 88 fby ( M ) φ( M ) := 1000000 fay ( M ) 1000000 if ≤ M ≤ 1689 otherwise 2000 fay ( x) fby ( x) Cuvature-moment curves before (dotted) and after (cont.) steel yielding Dotted line starts from origin and stops at the intersection pt.; cont line starts from the intersection pt 1000 0 1000 x 2000 −3 φ( 1725) = 1.455 × 10 164 x Moment Distribution of 3-point Loading of A Singly Supported Beam M b ( P , x) := P ⋅ x if ≤ x < −P L L ( x − L) 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computational mechanics I came to the University of Florida on December 31, 2001 173 ... Concrete Institute CFRP: Carbon Fiber Reinforced Polymer FRP: Fiber Reinforced Polymer GFRP: Glass Fiber Reinforced Polymer SGFRP: Sprayed Glass Fiber Reinforced Polymer xii Abstract of Dissertation... School of the University of Florida in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy A HYBRID FIBER REINFORCED POLYMER (FRP) SYSTEM OF CARBON FRP LAMINATE AND SPRAYED. .. the potential of CFRP laminates in flexural strengthening of reinforced concrete (RC) beams and that of sprayed glass FRP (GFRP) in shear strengthening to form a better hybrid FRP system Only the