Report on JSCE committee activities on LCA and LCC of FRP ......FRP1(standard) FRP2(enhanced) Materials Mold Assembly US-Japan Workshop on Life Cycle Assessment of Sustainable Infrastructure

RReport oneport on JSCE JSCE committee committee activities on activities on LCA LCA andand LCC LCC ofof FRP FRP infrastructureinfrastructure

Takumi ShimomuraTakumi Shimomura, , Nagaoka University of Technology, JapanNagaoka University of Technology, Japan

ItaruItaru NishizakNishizakii,, Public Works Research Institute, JapanPublic Works Research Institute, Japan

HirokazuHirokazu TanakaTanaka, , Shimizu Corporation, JapanShimizu Corporation, Japan

Application of FRP for civil Application of FRP for civil structures in Japanstructures in Japan

Reinforcement for concrete structuresBars and Grids as internal reinforcement (in 1980s)Sheet as external reinforcement (in 1990s)

US-Japan Workshop on Life Cycle Assessment of Sustainable Infrastructure Materials, Sapporo, Japan, October 21-22, 2009

JSCE committee on application of innovative structural material in civil engineering

FRP rod & grid for FRP rod & grid for reinforcement in concretereinforcement in concrete

Carbon FRP rods

Aramid FRP rods Pre-shaped FRP rods

In 1980s.Main reinforcementShear reinforcement



Application of Application of FRP rod & grid FRP rod & grid for concretefor concrete structuresstructures

Though used in some real structures, the number of application of FRP rods has not increased so much in Japan.

FRP Rod as tendon in bridge slab



FRP sheetFRP sheet

FRP sheet on concrete surface

Carbon fibre sheet Aramid fibre sheet



Seismic retrofit of existing RC Seismic retrofit of existing RC structures by FRP sheetstructures by FRP sheet

Increasing of seismic retrofit after Kobe Earthquake in 1995.

Carbon FRP sheet Aramid FRP sheet



Characteristics of FRP as Characteristics of FRP as structural materialstructural material

Advantages:Light weightHigh strengthHigh durability (no corrosion)

Disadvantages:High initial costBrittle failure (no yielding)



ProblemsProblems

Assessment items (light weight, high strength, high durability…) are just for traditional structural materials.Since FRP is new structural material, new assessment items, such as LCC and environmental aspects, should be taken into account so that their new merits are adequately evaluated.



LCC and LCA of environmental LCC and LCA of environmental aspects of FRP structuresaspects of FRP structures

Life Cycle Cost (LCC) and Life Cycle Assessment (LCA) of environmental impact of FRP structures are focused.JSCE committee on application of innovative structural materials in civil engineering

chairman: Prof. T. Uedavice chairman: Prof. S. Yamada2004-2005



Evaluated structureEvaluated structureUS-Japan Workshop on Life Cycle Assessment of Sustainable Infrastructure Materials, Sapporo, Japan, October 21-22, 2009


severe environmental condition (corrosion by sea salt)

FRP footbridge (Okinawa Road Park Bridge), 2000



Members in the bridgeMembers in the bridge

Main girders of the FRP bridge are made of hand-lay up FRP made of glass fiber and vinylester resin

Pultruded FRP made of glass fiber and vinylester resin is used for the stiffeners, decks and floor systems



Assessment of LCCAssessment of LCCLCC of the FRP footbridge were calculated based on actual data.Comparative structure: conventional PC footbridge with single span

Single span deck girder bridge with hollow post- tension concrete beams

PC footbridge

cross section of superstructure

pier



Cases Cases of of FRP bridgesFRP bridgesFRP bridge 1: standard FRP bridge (actually constructed)FRP Bridge 2: enhanced FRP bridge

Aluminum handrailDurable stainless steel bolts for the joint part of the main girderSharing the mold by two bridges

FRP bridges are assembled in Tokyo and transported to Okinawa by ship.



Cases Cases of PC bridgesof PC bridges:: corrosion protectioncorrosion protection

PC bridge 1:no corrosion protection

PC Bridge 2:coated reinforcing barscoated PC tendon

PC bridge 3:coated reinforcing barscoated PC tendonsurface coating

epoxy coated reinforcement

surface coating for concrete

Cl-O2

H2 O



Method of assessment of LCCMethod of assessment of LCC

Lc = Ic + Mc (+ Dc)Lc: Life cycle cost of FRP/PC bridgeIc: Initial costMc: Maintenance costDc: Demolition cost, which was not considered here

Discount rate to discount future costs to the base year was not considered.LCC of FRP bridge was calculated according to actual data of Okinawa Road Park Bridge as much as possible.LCC of PC bridge was calculated based on experiences of similar structures.

Initial cost of FRP bridgesInitial cost of FRP bridgesUS-Japan Workshop on Life Cycle Assessment of Sustainable Infrastructure Materials, Sapporo, Japan, October 21-22, 2009


Parts and items Material

FRP superstructure FRP superstructure (enhanced)

Weight (kg)

unit cost (JPY)

Subtotal (JPY)

Subtotal (JPY) Modified point

Girders & stiffener Hand-lay up 8,794.7 2,500 21,986,750 21,986,750

Cross frame & deck Pultrusion 9,080.2 1,500 13,620,300 13,620,300

Handrail Pultrusion 5,000,000 2,000,000 Change to Aluminum handrail

Sub-total (FRP members) 17,874.9 40,607,050 37,607,050

Joint members Stainless 2,972.8 7,500,000 5,250,000 Neglect beauty of the bridge

Bolts Stainless 1,000,000 1,000,000

Mold for HLU 10,000,000 5,000,000Construct 2 bridges at the

same time

Cost for assembly 8,000,000 8,000,000

Cost for painting 3,500,000 2,500,000 Exclude handrail

Cost for shipping (Tokyo to Okinawa) 3,000,000 3,000,000

Total 73,607,050 62,357,050

FRP1(standard) FRP2(enhanced)

Mat

eria

ls

Mold

Asse

mbl

y



Calculated initial cost of Calculated initial cost of FRP/PC bridgesFRP/PC bridges

FRP1 FRP2 PC1 PC2 PC3Superstructure 73.60 62.35 48.24 50.62 54.37

Substructure 6.91 6.91 10.13 10.13 10.13

Total initial cost

80.51 69.26 58.37 60.75 64.50

million JPY (=11000 USD)



Maintenance of FRP bridgesMaintenance of FRP bridges

periodical inspectionrepair works

change of stainless steel bolts at jointevery 5 years for FRP1 (standard)every 50 years for FRP2 (enhanced)

painting of FRPevery 120 years (rate of loss due to UV ray: 0.5μm/year)


FRP橋梁　上部工

0

10

20

30

40

50

60

0 50 100 150

経過年

補修費用（百万円）

FRP歩道橋

FRP歩道橋（改良型）

year

FRP1 (standard) FRP2 (enhanced)

mai

nten

ance

cos

t (m

illio

n JP

Y)

FRP bridge 1: standard FRP bridgeFRP Bridge 2: enhanced type

- Aluminum handrail- Durable stainless steel bolts for the joint part of the main girder- Sharing the mold by two bridges

Calculated Calculated maintenance cost maintenance cost of FRP bridgesof FRP bridges




MMaintenance of PC bridgesaintenance of PC bridgesperiodical inspection repair works

Penetration of chloride ion into the concrete is calculated.Repair is carried out when the calculated chloride concentration at steel reinforcing bars reached 1.2 kg/m3.Repair method: replacement of concrete cover, surface coatingThe life of surface coating: 15 or 30 years

Cl-

removed

polymer cement mortar

surface coating

Cl-

2

2

xCD

tC

∂∂

=∂∂



Calculated maintenance cost Calculated maintenance cost of PC bridgesof PC bridges

PC bridge 1:- no corrosion protection

PC Bridge 2:- coated reinforcing barscoated PC tendon

PC bridge 3:- coated reinforcing barscoated PC tendonsurface coating

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

0 20 40 60 80 100 120

経過年

維持管理費用（万

円）

ケース１（被覆材15年間隔補修）

ケース１（被覆材30年間隔補修）

ケース２

ケース３（被覆材15年間隔補修）

ケース３（被覆材30年間隔補修）

year

PC1 (repair every 15years) PC1 (repair every 30years) PC2 PC3 (repair every 15years) PC3 (repair every 30years)

10

20

30

40

50

60

70

80

mai

nten

ance

cos

t (m

illio

n JP

Y)



Calculated total LCC of FRP/PC Calculated total LCC of FRP/PC bridgesbridges

million JPY (=11000 USD)

FRP1 FRP2 PC1 PC2 PC3a PC3bInitial Cost

80.51 69.26 58.37 60.75 64.50 64.50

Maintenance

Cost10.00 3.50 42.50 0 27.00 9.00

50years LCC

90.51 72.76 100.87 60.75 91.50 73.50

100years LCC

100.51 76.26 127.87 85.25 118.50 91.50

repair every 15years

repair every 30years



LLCA of COCA of CO 22 emissionemission

FRP bridge: actually constructed

PC bridge: Single span deck girder bridge with hollow post-tension concrete beams

FRP bridges are assembled in Tokyo and transported to Okinawa by ship.

PC bridge is cast on site.

Evaluation scheme of life cycle Evaluation scheme of life cycle COCO 22 emission of bridges emission of bridges

Materials s tageMain b eam manufacture Bridge deck manufacture

A ssembling(Tokyo )

Marine trans portation Tokyo→Okinawa2,000km

Land torans portation 2km

Installation By truck crane

Us ing

Dis pose & Recycle

Cons truction stage

Us ing s tage

is pose & Recycle Stag e

Ou t of sbject

Concrete mixing

Cas ting in place

Curing

By co ncrete pump &vibrator

FRP footbridge

Reinforcement Steel Cement, Agg regate

Reinforcement steel & form assebling

General curing

Land trans portation50km

Land transp ortation300km

PC footbridge

Ou t of sbject

Land transportation20km

Lan d trans portation20km

Land transpo rtation20km

Using

Dispo se & Recycle

Out of sbject

Out of sbject

Service stage

Demolition stage Demolition Demolition

Service ServiceNot considered

Not considered

Not considered

Not considered

Materials s tageMain b eam manufacture Bridge deck manufacture

A ssembling(Tokyo )

Marine trans portation Tokyo→Okinawa2,000km

Land torans portation 2km

Installation By truck crane

Us ing

Dis pose & Recycle

Cons truction stage

Us ing s tage

is pose & Recycle Stag e

Ou t of sbject

Concrete mixing

Cas ting in place

Curing

By co ncrete pump &vibrator

FRP footbridge

Reinforcement Steel Cement, Agg regate

Reinforcement steel & form assebling

General curing

Land trans portation50km

Land transp ortation300km

PC footbridge

Ou t of sbject

Land transportation20km

Lan d trans portation20km

Land transpo rtation20km

Using

Dispo se & Recycle

Out of sbject

Out of sbject

Service stage

Demolition stage Demolition Demolition

Service ServiceNot considered

Not considered

Not considered

Not considered



material stage

construction stage

FRP bridge PC bridge

Unit of COUnit of CO 22 emissionsemissionsUS-Japan Workshop on Life Cycle Assessment of Sustainable Infrastructure Materials, Sapporo, Japan, October 21-22, 2009


Unit Unit of carbon dioxide emissionsFRP(Hand-lay up） kg 4.97 kgCO2/kgFRP(Pult ruded） kg 3.09 kgCO2/kg

kg 0.0918 kgCO2/kgm3 211.1 kgCO2/m3

Reinfoecement steel kg 0.755 kgCO2/kgPrestressing steel wire kg 1.31 kgCO2/kg

Steel pipe pile kg 1.25 kgCO2/kgMarine t ransportat ion t*km 0.039 kgCO2/t*kmLand t ransportat ion t*km 0.154 kgCO2/t*km

Construct ion Concrete m3 39.0kgCO2/m3

Materials

Transportat ion

Heading

Concrete（Fc27N/mm2）

References: - Japan Reinforcement Plastic Societ: FRP Whoever Use -FRP handbook-, (In Japanese) (2003) - Japan Society of Civil: Engineers: Environmental impact evaluation of concrete (Part2), (In Japanese) (2004) - Ministry of Land Infrastructure and Transport (Japan). Data of the unit of carbon dioxide emissions of transportation for 2003 (2006)

Calculated Calculated COCO 22 emission of emission of bridgesbridges



0

5 104

1 105

1.5 105

2 105

FPR footbridge PC footbridge

SuperstructureSubstructure

Amou

nt o

f car

bon

diox

ide

emiss

ons(

kg)

(Mat

eria

ls sta

ge)

0

5000

1 104

1.5 104

2 104

FPR footbridge PC footbridge

SuperstructureSubstructure

Am

ount

of c

arbo

n di

oxid

e em

issio

ns(k

g)(C

onstr

uctio

n sta

ge)

Amount of CO2 emission at material stage

Amount of CO2 emission at construction stage

FRP bridge PC bridge FRP bridge PC bridge

PC footbridgeFRP footbridge

superstructure substructure

superstructure substructure

Calculated Life Cycle Calculated Life Cycle COCO 22 emission of bridgesemission of bridges



Amount of CO2 emission at material and construction stage

0

5 104

1 105

1.5 105

2 105

FRP footbridge PC footbridge

Materials stageConstruction stage

Am

ount

of a

rbon

dio

xide

emiss

ions

(kg)

(Mat

eria

ls &

Con

stru

ctio

n sta

ge)

FRP bridge PC bridge

material stage construction stage

ConclusionsConclusionsFRP bridge can be enough competitive with conventional PC bridge even in its initial costs.FRP bridge becomes more effective when longer life is required under severe corrosive environment.Life cycle CO2 emissions of FRP bridge isreduced than that of PC footbridge. This is because the weight of superstructure of FRP bridge is much lighter than that of PC footbridge.



Documents

Report on JSCE committee activities on LCA and LCC of FRP ......FRP1(standard) FRP2(enhanced) Materials Mold Assembly US-Japan Workshop on Life Cycle Assessment of Sustainable Infrastructure