SUREbridgedemonstration event1 September 2017

FRP Composites as a Solution for Sustainable

Construction

Dr Martijn VeltkampHead of engineering departmentFiberCore Europe, Rotterdam, NLveltkamp@fibercore-europe.com

Ronald Grefhorst

Teodor Gheorghe

Outline

1. Why FRP composites?2. Material product3. Advantages of hybrids

• With steel• With concrete: SUREbridge

Advantages of the FRP material

• Strong and safe• Maintenance free• No corrosion, no rot• Fire resistance• Freedom of shape and design • Low life cycle costs• Light weight• Integral structures• Easy to relocate• Durable and recyclable• Chemically resistant• …

Superior material

So when all this possible, why wasn’t it applied in civil engineering structures like

road bridges and lock gates?

So when all this possible, why wasn’t it applied in civil engineering structures like

road bridges and lock gates?

-Because it can delaminate, debond or crack

Classic sandwich, Achilles heel

Slamming, Stena Discovery, 1998 Blast resistance

Glass Fibre Fabric box plate:Flanges, integrally connected by websFlanges 0ᵒ/ ±45ᵒ fabric, web 90ᵒ/±45ᵒ fabric

Thesolution:

Unique characteristics:• Fibers covering all corners• Holding the bottom skin = holding the panel

Any strength, any thickness

Glass Fibre Fabric box plate:Flanges, integrally connected by websFlanges 0ᵒ/ ±45ᵒ fabric, web 90ᵒ/±45ᵒ fabric

Rotterdam, Gaaspdimensions : 10 x 2 myear : 2009

FRP bridges: it is as simple as this

Timeline

Fly

Regulations to fly

1997: First bridge by founder of FiberCore, Jan Peeters

450 realised structures

CUR96:2003 FRP design guidance

CUR96:2015 expanded FRP

design guidance

Where FRP stops, go hybrid

Strength is rarely the limit of FRP.

Hybrids offer advantages in situations with:

• Large spans• High slenderness requirements• High stiffness requirements

• Existing structures below strength• Existing overly heavy structures

New-built

Refurbishments

Where FRP stops, go hybrid

True hybrids:Transfer of longitudinal shear stresses between existing and new

Semi-hybrids:Combination of multiple materials

142m viaduct: steel truss with an InfraCore deck

ClientLead

consultantMain

contractorSteel

contractorDesign &

buildLocal

authority

Cross section bridgeSteel truss with FRP floor

Jointcomposite-steel

Curb with ducts and cables

underneath

steel

Traffic bridge Utrecht, across highway A27dimensions : 142 x 6,2 mspan : 6,2 mtraffic class : class 600 kNyear : 2011-2012

Joint steel-composite2011 state-of-the-art and meanwhile improved

Steel plate truss

Composite deck (InfraCore)

Pin through steel and deck

bonded joint

Demanding clients

Winner Innovation Award

FRP on steel:replacement of concrete for FRP deck

Typical refurbishment situation:• Concrete deck of

insufficient capacity• Arch superstructure does

have sufficient capacity• Limit self weight

Span: 62m, width: 4,5m

Typical challenges of an FRP deck on a steel superstructure

SUREbridgeSustainable refurbishment of existing (concrete) bridges

• Restoring the load carrying capacity of aged and deteriorated bridges

• By combining two technologies: – InfraCore FRP decks on top

for deck restoration and additional compressive capacity

– Prestressed carbon external reinforcement on underside for additional tensile capacity

State of the art

Prototype analysis

Client demands

Connection deck-to-concrete

Fabrication

Partial tests

Deck-design and connections between deck-segments

Full-scale tests

Fabrication

Develop design tool

Operating procedure

2015 2016 2017 2018

WP2

WP3

WP4

progress

Phasing and progress

Pilot projectNext step:

1. Remove asphalt 2. Refurbish concrete and reinforcement

3. Apply carbon strips and prestress

4. Install bolts for vertical positioning of decks

5. Install InfraCore deck panels on the bolts

6. Apply grouting betweenexisting and new deck

SUREbridge installation sequence

Finishings to the SUREbridge-system

Refurbishment completed

Thank you for your attention!