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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
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.
MST-BAR™: Typical Preparation for Mechanical Testing
Typical package of MST-BAR ™ for CSA & ACI tests. All MST-BAR ™ were shipped to University of Sherbrooke to be tested.
MST-BAR™: Typical Preparation for Mechanical Testing
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”
“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
“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”
Crack Details
“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”
Crack Pattern at Failure
“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”
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
Description Quantity $/Unit Total
Form Work 2800 m2 120 $/m2 $ 336,000.00
Rebar & Installation
50,000 Kg 3 $/kg $ 150,000.00
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 $ 877,300.00
2800m2 - Roof Slab Epoxy Coated Rebar-Reinforced Deck-Initial Cost
Description Quantity $/Unit Total
Form Work 2800 m2 120 $/m2 $ 336,000.00
Rebar & Installation
42,160m 3-6 $/m $ 211,000.00
Concrete(30MPa) & Installation
t=200mm Area=2800Volume=560m3
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
Description Quantity $/Unit Total
Concretedemolition
980 m2 125 $/m2 $ 122,500.00
Rebar & Installation
5,000 KgONLY 20% TOP
2.5 $/kg $ 12,500.00
Concrete(30MPa) & Installation
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
Over Burden Asphalt 2800m2
Gravel 2800m254 $/m2
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
Description Quantity $/Unit Total
Concretedemolition
980 m2 125 $/m2 $ 122,500.00
Rebar & Installation
5,000 KgONLY 20% TOP
3 $/kg $ 15,000.00
Concrete(30MPa) & Installation
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
Over Burden Asphalt 2800m2
Gravel 2800m254 $/m2
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!!!
RE&RE:REMOVAL & REPLEACMENET
Epoxy Coated Steel
Description Quantity $/Unit Total
Concretedemolition
0 0 $/m2 $ 0
Rebar & Installation
0 0 $/kg $ 0
Concrete(30MPa) & Installation
0 0 $/m3 $ 0
Blast Track 0 0 $/m2 $ 0
Water Proofing(DoubleSystem)(RE&RE)
35 $/m2
REM. 6 $/m2
$ 0
Over Burden Asphalt 2800m2
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!!!
RE&RE:REMOVAL & REPLEACMENET
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