Introduction to GFRP Rebar in a bridge case study

1. INTRODUCTION TO FIBERGLASS
REBAR TECHNOLOGY

2. OUTLINE
• INTRODUCTION TO FRP REBAR
• COMPARISON TO OTHER MATERIALS
• FEATURES OF FRP REBAR
• APPLICATIONS
• LIFE CYCLE COST
• CASE STUDY

3. The Pultrusion Process

4. FRP Rebar Composition
Fibres (Reinforcements)
Resins (Polymers)
Fillers
Additives
Fibres – Mechanical strength
Resins – Chemical resistance

5. FRP Rebar Composition
• Main functions of the Fibres:
• Carry load
• Provide strength and stiffness
3
2
1

6. FRP Constituents Functions
• Main functions of the Resin:
• Transfers stresses between fibers
• Provides lateral support against buckling
• Protects fibers from mechanical and environmental
damage
– Thermoset Resins are typically used:
• Heat cured vinyl ester
• Irreversible process
• Cannot be deformed upon curing

7. BENDING PROCESS

8. Sand Coating Process

9. COMPARISON TO
OTHER MATERIALS

10. TENSILE STRENGTH
X 103 psi
100
90
80
70
60
50
40
30
20
10
0
Steel Pultrusion 70% roving Aluminum

11. DENSITY
8
7
6
5
g/cc 4
3
2
1
0
Steel Aluminum Pultrusion 70% Pultrusion 50%
roving mat & roving

12. 4000 Carbon FRP
Constraint
(MPa)
1250 Glass FRP
400 Steel
40 Concrete
Displacement

13. Fatigue
Comparison of GFRP, CFRP and STEEL Panels
Fatigue under 60 t Load Punching Shear Cycles to
Failure Mode Failure
3.5 @ 60 t
3.0
23,162
Crack Width (mm)
2.5 STEEL
STEEL
2.0
1.5 GFRP 198,863
1.0 CFRP
CFRP
0.5
0.0 420,684
100 1,000 10,000 100,000 1,000,000 GFRP
No. of Cycles (Nos.)

14. Composite Rebars
Features

15. Key features
• Corrosion resistance (Na+, Cl-, Alkalis…)
• Electromagnetic Neutrality
• Low density (2 g/cm3)
• Thermal Conductivity (2.0 BTU/ft2/hr/ºF/in)

16. Key features
FRP composites is a great solution to the
problems associated with the aging infrastructure
of Canada for the following reasons:
– Corrosion resistance :
• Reduce repair and maintenance cost.
• Enhance life duration of a concrete structure.
• Help obtain better life cycle cost.
– Electromagnetic Neutrality :
• Do not bloc radio waves.
• Will not interfere with radar waves.
• Will ease communications through the structure (mobile phone).

17. Key features
• FRP composites is a great solution to the problems associated with the
aging infrastructure of Canada for the following reasons:
– Low density :
• Saves on transportation costs.
• Easier and faster construction with less workers and equipment.
– Excellent electrical isolation properties :
• Resistance to electrochemical corrosion (no galvanic corrosion).
• No lost of current through the structure.
– Fabrication versatility of FRP allows the geometry, strength, stiffness,
and durability characteristics of the member to be tailored for each
particular application.

18. THE APPLICATIONS

19. BRIDGES

20. BRIDGES

21. BRIDGES

22. BRIDGES

23. BRIDGES

24. BRIDGES

25. OTHERS

26. APPLICATIONS - CORROSION
• PARKING GARAGE.

27. APPLICATIONS - CORROSION
• Offshore Loading Quay (St. Lawrence Seaway)

28. APPLICATIONS - CORROSION
• Hall’s Harbour (Nova Scotia)

29. APPLICATIONS - CORROSION
• Water Desalination Inlet – Saudi Arabia

30. APPLICATIONS - CORROSION
• MARINES RAMPS.

31. APPLICATIONS - CORROSION
• MARINES RAMPS.

32. APPLICATIONS - CORROSION
• CONRETE HIGHWAY MTL 40 KIRKLAND

33. LIFE CYCLE COST
Engineering and evaluation
This portion of the presentation is inspired from the
study released by Dr. Gordon Spark ,Ph.D. , P.Ing.
(University of Saskatchewan) for ISIS Canada.
33

34. Four (4) concepts has been studied
Reinforcement Concrete Cover
CONCEPT SUP BOTTOM EXTERNAL TYPE THICKNESS SURFACE MEMBRANE
ASPHALTE
1 EPOXY EPOXY NONE HP 225mm YES
90mm
ASPHALTE
2 MMFX-2 MMFX-2 NONE HP 225mm YES
90mm
ASPHALTE
GFRP EPOXY STRAP HP 225mm YES
3 90mm
HIGH
DENSITY
4 GFRP GFRP STRAP HP 200mm NO
CONCRET
E 50mm
34
HP = Haute Performance

35. COMPARAISON OF THE INITIAL
COST
GFRP CONCEPT IS APPROXIMATELY 0 to 10 % HIGHER 2005
1400
1360
1350 1315
1300
1258
1250 1216
1200
1150
1100
1. Époxy sur 2. MMFX sur 3. Époxy sur 4. GFRP sur
Époxy MMFX piliers/GFRP piliers/GFRP
PW Cost ($'000)
35

36. COMPARAISON OF THE
MAINTENANCE AND DEMOLITION
COST
GFRP SOLUTION IS 45 TO 60% LOWER IN COST
1200 1169 1193
1000 891
800
600 493
400
200
0
1. Époxy sur 2. MMFX sur 3. Époxy sur 4. GFRP sur
Époxy MMFX piliers/GFRP piliers/GFRP
PW Cost ($'000)
36

37. ALSO TAKING INTO ACCOUNT THE UNCERTAINTY
RELATED TO THE USE OF THE DIFFERENT MATERIALS:
THE CONCEPT USING GFRP MAKE OWNERS SAVE UP TO 30%
COMPARE TO EPOXY.
Distribution des coûts de cycle de vie utile
3000 2685
2515
2500 2222
PW Cost ($'000)
2000 1773
1500
1000
500
0
1. Époxy sur 2. MMFX sur 3. Époxy sur 4. GFRP sur
Époxy MMFX piliers/GFRP piliers/GFRP
37

38. CASE STUDY
• TITLE : COMPARISON OF DIFFERENT HIGHWAY
BRIDGEDECK REINFORCEMENT DESIGNS.
• COMPARISON OF INITIAL COST.

39. CASE STUDY
• There is considerable differences in mechanical
properties of different FRP rebar mainly in their modulus
of elasticity.
• Could these differences in the GFRP mechanical
properties affect the design of concrete deck slabs?
• Could the design of concrete bridge deck slabs using
GFRP bars with superior mechanical properties result in
reducing the required reinforcement consequently saving
the cost.
• How these design compare to designs made with other
so called corrosive resistant material ; galvanized steel
and epoxy coated steel.

40. CASE STUDY
• This study aims to answer these questions by
designing a typical slab-on-girder concrete
bridge deck using four different types of
reinforcement bars with different mechanical
properties.
• One recently constructed concrete bridge deck
reinforced with FRP bars (Melbourne Bridge) is
taken as an example in the design.
• The Canadian Highway Bridge Design Code,
CHBDC (CAN/CSA-S6-00, 2000) and the
updated version were used to conduct this
design (New Code, CHBDC 2005).

41. CASE STUDY
• The bridge is a girder type consisting of four prestressed concrete
girders (Type NETB) continuously supported over three spans with
a total length of 89.420 m.
• The deck is a 200-mm thickness concrete slab.
• The deck has overhangs of 1.52 m on each side.
A B C D
14.00 m
2% 2%
200 mm
1.72 m 3.52 m 3.52 m 3.52 m 1.72 m

42. RESULTS
Bar List for Galvanized Steel.
Configuration of Quantit Total Price Calculated Total
Identification Length (mm) Designation
reinforcement y Length (m) ($/m) Price ($)
As=833,33 mm2/m 15M
D1 11485 15M 864 9923,0 3,64 $ 36 119,87 $
@ 240mm
As=1250 mm2/m 15M
D2A 10600 15M 465 4929,0 3,64 $ 17 941,56 $
@ 160mm
As=1250 mm2/m 15M
D2B 3650 15M 465 1697,3 3,64 $ 6 177,99 $
@ 160mm
As=1250 mm2/m 15M
D2E 8865 15M 543 4813,7 3,64 $ 17 521,85 $
@ 160mm
As=1250 mm2/m 15M
D2F 5390 15M 543 2926,8 3,64 $ 10 653,44 $
@ 160mm
As=1250 mm2/m 15M
D5 2735 15M 1086 2970,2 3,64 $ 10 811,56 $
@ 160mm
27259,965m
99 226,27 $

43. RESULTS
Bar List for Epoxy coated steel.
Configuration of Length Total Length Price Calculated Total
Identification Designation Quantity
reinforcement (mm) (m) ($/m) Price ($)
As=833,33 mm2/m 15M @ D1 11485 15M 864 9923.0 3.48 $ 34 508.84 $
240mm
As=1250 mm2/m 15M @ D2A 10600 15M 465 4929.0 3.48 $ 17 141.33 $
160mm
As=1250 mm2/m 15M @ D2B 3650 15M 465 1697.3 3.48 $ 5 902.44 $
160mm
As=1250 mm2/m 15M @ D2E 8865 15M 543 4813.7 3.48 $ 16 740.34 $
160mm
As=1250 mm2/m 15M @ D2F 5390 15M 543 2926.8 3.48 $ 10 178.28 $
160mm
As=1250 mm2/m 15M @ D5 2735 15M 1086 2970.2 3.48 $ 10 329.34 $
160mm
27259,965m
94 800.56 $

44. Bar List for comparatives
Configuration of Length Total Length Price Calculated Total
Identification Designation Quantity
reinforcement (mm) (m) ($/m) Price ($)
Afrp=1165 mm2/m No16 @
D1 11485 16 1184 13598,24 2,71 $ 36 851,23 $
170mm
Afrp=1722 mm2/m No16 @
D2A 13655 16 784 10705,52 2,71 $ 29 011,96 $
115mm
Afrp=1722 mm2/m No16 @
D2E 13655 16 784 10705,52 2,71 $ 29 011,96 $
115mm
Afrp=861 mm2/m No16 @
D5 3650 16 784 2861,6 2,71 $ 7 754,94 $
230mm
37870,88m
102 630,08 $
Bar List for our product.
Configuration of Designati Total Length Price Calculated Total
Identification Length (mm) Quantity
reinforcement on (m) ($/m) Price ($)
Afrp=921 mm2/m No16 @
D1 11485 16 928 10658,08 3,23 $ 34 425,60 $
215mm
Afrp=1366 mm2/m No16 @
D2A 13655 16 621 8479,755 3,23 $ 27 389,61 $
145mm
Afrp=1366 mm2/m No16 @
D2E 13655 16 621 8479,755 3,23 $ 27 389,61 $
145mm
Afrp=683 mm2/m No16 @
D5 3650 16 621 2266,65 3,23 $ 7 321,28 $
290mm
29884,24m
96 526,10 $

45. INITIAL COST COMPARISON
Rebar type Quantity (m) Initial Cost ($)
Galvanized steel 27 260 99 226
Epoxy coated steel 27260 94 801
29 884 96 526
Our Product

46. CASE STUDY
• TITLE : COMPARISON OF DIFFERENT DESIGNS
SEAWALL SLAB REINFORCEMENT.
• COMPARISON OF INITIAL COST.

47. CASE STUDY
• This study aims at comparing design
differences for a seawall slab with different
types of reinforcement bars.
• It uses a slab design we recently worked
on as an example.
• The ISIS Canada Guidelines as well as
the CAN/CSA-S806 Code were used to
conduct this design.

48. RESULTS
Bar List of a slab reinforced with Stainless Steel.
Total length Price Total per item
Configuration ID Length (mm) Designation Qty
(m) ($/m) ($)
15M STIRRUPS A 1450 15M 90 130.5 $ 16.89 $ 2 204.15
15M @ 4000mm B 4000 15M 90 360.0 $ 16.89 $ 6 080.40
15M @ 8150mm C 8150 15M 34 277.1 $ 16.89 $ 4 680.22
767.6 m
$ 12 964.77
B
A C

49. RESULTS
Bar List of a slab reinforced with STANDARD V-ROD.
Total length Price Total per item
Configuration ID Length (mm) Designation Qty
(m) ($/m) ($)
$ 2.71
15M STIRRUPS A 1450 16 152 220.4 $ 1 053.36
+ bend
15M @ 4000mm B 4000 16 150 600.0 $ 2.71 $ 1 626.00
15M @ 8150mm C 8150 16 76 619.4 $ 2.71 $ 1 678.57
1 439.8m
$ 4 357.93
B
B
C
A C
A

50. RESULTS
Bar List of a slab reinforced with V-ROD HM.
Total length Price Total per item
Configuration ID Length (mm) Designation Qty
(m) ($/m) ($)
$ 2.71
15M STIRRUPS A 1450 16 92 133.4 $ 637.51
+ bend
15M @ 4000mm B 4000 16HM 90 360.0 $ 3.23 $ 1 162.80
15M @ 8150mm C 8150 16HM 46 374.9 $ 3.23 $ 1 210.93
868.3m
$ 3 011.24
B
B C
B C
A
A A C

51. INITIAL COST COMPARISON
Rebar type Quantity (m) Initial Cost ($)
Stainless Steel 767.6 12 965
868.3 3 011
V-ROD HM

52. CONCLUSION
CSA CHBDC
S806-0
• Codes are available: 2
2000
ISIS ACI
2001 440.1R-
• Design guides are available: 01
• Certification of FRP rebar is available (Can & USA).
• Competitive solution against corrosion.