HISTORY - FRP Fiber Reinforced Materials

1
HISTORY - FRPFiber Reinforced Materials

• Straw in Clay (Brick, Roof, Walls)
• Glass Fibers in Concrete
• Glass Fibers in Polymer

2
HISTORY - FRPPOST WW-II APPLICATIONS

• Boat Hulls
• Radomes
• Minesweeping Vessels
• Bath Tubs
• Covers

HS, CR, LW - New Developments in Filament
Winding and Pultrusion
3
HISTORY - FRPPOST WW-II APPLICATIONS-2

• Pressure Vessels
• Submarine Parts
• Rocket Shells
• Aircraft Components
• Automobile Bodies Parts

4
HISTORY - FRPPOST WW-II DOMESTIC APPLICATIONS

• Bath Tubs
• Covers
• Railings
• Housing Components
• Architectural Components
• Ladders
• Electrical Equipment

5
HISTORY - FRPPOST WW-II RECREATIONAL USES

• Fishing Rods
• Tennis Rackets
• Ski Equipment
• Golf Clubs
• Recreation Boats
• Skates

6
FRP CONSUMPTION(IN MILLION POUNDS)
Source SPI CI, April 99
7
FRP - CIVIL STRUCTURESCURRENT FIELD ACTIVITIES

• Pedestrian Bridges
• Highway Bridges
• Seismic Retrofit Columns
• Bridge Strengthening
• Bridge Repairs

8
FRP TECHNOLOGYCHARACTERISTICS

• High Strength
• High Resistance to Corrosion and Chemical
• High Resistance to Elevated Temperature
• High Resistance to Abrasion
• Toughness
• Fatigue
• Light Weight

9
FRP TECHNOLOGYADVANTAGES

• Ease in Fabrication, Manufacturing, Handling, and
  Erection
• Year-Round Construction
• Short Project Time Delivery
• High Performance
• Durability (Jury Still Out)
• Excellent Strength-to-Weight Ratio

10
FRP TECHNOLOGYDISADVANTAGES -1

• High First Cost
• Creep and Shrinkage
• Potential for Environmental Degradation (Alkalis
  Attack, UV Radiation Exposure, Moisture
  Absorption, etc.)
• Consistency of Material Properties

11
FRP TECHNOLOGYDISADVANTAGES - 2

• Global and Local Buckling
• Aerodynamic Instability With Lightweight
• Requires Highly Trained Specialists
• Lack of Standards and Design Guides
• Limited Joining and Connection Technology
  (Adhesive joints, fasteners)

12
FRP TECHNOLOGYPUBLIC CONCERNS

• Fire/Flame Resistance
• Smoke Toxicity
• Fuel Spills
• Vandalism/Theft
• Inspectibility
• Repairability

13
MANUFACTURING PROCESSCOMMON TO CIVIL APPLICATIONS

• Pultrusion
• Filament Winding
• Layup

14
WHAT IS FRP COMPOSITESCOMPONENTS

• Fiber Reinforcement
• Resin Matrix
• (Fiber-Matrix Interphases)
• Fillers
• Additives

15
FRP TECHNOLOGYMECHANICAL PROPERTIES

• Fiber Types
• Fiber Orientations
• Fiber Architecture
• Fiber Volume (30-70)

16
FRP TECHNOLOGYFIBER TYPES

• Glass
• Aramid
• Carbon (Graphite)
• Boron
• Polyvinyl alcohol (PVA) (Available in Japan)

17
FRP TECHNOLOGYFIBER OREIENTATION

• 0 Degree (Parallel - Warp)
• 90 Degrees (Transverse - Weft)
• Between 0 and 90 Degrees (Biased)
• (e.g. 0/45/90/-45/0)

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FRP TECHNOLOGYFIBER ARCHITECTURE

• Braiding (2D 3D)
• Knitting
• Weaving
• Stitched
• Chopped

19
FRP TECHNOLOGYCARBON FIBER

• Three Polymer Precursors Polyacrylonitrile
  (PAN) Rayon
  Pitch
• Anisotropic Materials
• Linear Elastic to Failure
• Failure by Rupture

20
FRP TECHNOLOGYARAMID FIBER

• Aromatic Polyamides
• Kevlar 29
• Kevlar 49
• Anisotropic Materials
• Linear Elastic to Failure
• Failure by Rapture

21
FRP -TYPICAL PROPERTIES
Source Tonen Energy Corp
22
FRP BRIDGE TECHNOLOGYFIBER PROPERTIES
Carbon (600 ksi)
4
Aramid (500 ksi)
3
E-glass (350 ksi)
fiber stress (Gpa)
2
1
1
2
3
4
fiber strain ()
23
FRP TECHNOLOGYRESIN SYSTEM

• Thermoplastics (melts when heated, solidifies
  when cooled, no permanent curing)
• Thermosets (cures permanently by irreversible
  cross linking at elevated temp.)

24
FRP TECHNOLOGYRESIN FORMULATIONS

• Viscosity
• Reactivity
• Resiliency
• High Deflection Temperature (HDT)

25
FRP TECHNOLOGYRESIN TYPES

• Unsaturated Polyesters
• Epoxies
• Vinyl Esters
• Polyurethanes
• Phenolics

26
FRP - RESIN SYSTEMUNSATURATED POLYESTERS - 1

• 75 Resins Used in USA
• Condensation Polymerization of Dicarboxylic Acids
  Dihydric Alcohols
• Contains Maleic Anhydride or Fumaric
  Acid

27
FRP - RESIN SYSTEMUNSATURATED POLYESTERS - 2

• Dimensional Stability
• Affordable Cost
• Ease in Handling, Processing, Manufacturing
• High Corrosion Resistant Fire Retardants
• Best Value for Performance Strength

28
FRP - RESIN SYSTEMEPOXIES

• Glycidyl Ethers and Amines
• Customized Properties
• Limited Workability
• Sensitive to Curing Agents
• High Performance
• High First Cost

29
FRP - RESIN SYSTEMVINYL ESTERS

• Good Workability
• Fast Curing
• High Performance
• Toughness
• Excellent Corrosion Resistance

30
FRP - RESIN SYSTEMPOLYURETHANES

• Polyisocyanate Polyol
• Reaction or Reinforced Injection Molding Process
• High Performance
• Toughness
• Excellent Corrosion Resistence

31
FRP - RESIN SYSTEM PHENOLICS

• Phenols Formaldehyde
• Resole - Alkaline (F/P gt 1.0) (Cured
  by Heat)
• Novolac - Acidic (F/P lt 1.0) (Cured by Chemical
  Reaction)
• Resistance to High Temperature
• Good Thermal Stability
• Low Smoke Generation

32
FRP TECHNOLOGY FILLERS

• Control Composites Cost
• Improved Mechanical Properties
• Improved Chemical Properties
• Reduced Creep Shrinkage
• Low Tensile Strength
• Fire Retardant Chemical Resistant

33
FRP TECHNOLOGYFILLER TYPES

• Calcium Carbonate
• Kaolin
• Alumina Trihydrate
• Mica Feldspar
• Wollastonite
• Silica, Talc, Glass

34
FRP TECHNOLOGYADDITIVES

• Improved Material Properties
• Aesthetics
• Enhanced Workability
• Improved Performance

35
FRP TECHNOLOGYADDITIVE TYPES

• Catalysts
• Promoters
• Inhibitors
• Coloring Dyes
• Releasing Agents
• Antistatic Agents
• Foaming Agents

36
FRP TECHNOLOGYSMART MATERIALS

• Innovative Design and Application
• Customized Product for High Performance
• Versatility
• Complex Design Process
• Materials, Processing, Configurations

37
FRP - DESIGN FEATURES

• Avoid Abrupt Thickness Change
• Take Advantage of Geometric Shapes
• Take Advantage of Hybrid System
• Use Bonded Assemblies Joints
• Provide Good Details on Connections

38
FRP - DESIGNAVOID ABRUPT THICKNESS

• Inefficient By Thickness
• Avoid Stress Risers
• Consider Stress Flow
• Consider Load Paths
• Understand Structural Behavior

39
FRP - DESIGN FEATURES

• Avoid Abrupt Thickness Change
• Take Advantage of Geometric Shapes
• Take Advantage of Hybrid System
• Use Bonded Assemblies Joints
• Provide Good Details on Connections

40
FRP - DESIGNGEOMETRICAL SHAPES

• Low Stresses
• Optimize Design - Balance Criteria (Stress,
  Deflection, and Stability)
• Use Flanges, Ribs, Stiffeners
• Use Honeycomb or Box Cells, Tubes
• Proportioning and Orienting Cells

41
FRP - DESIGN FEATURES

• Avoid Abrupt Thickness Change
• Take Advantage of Geometric Shapes
• Take Advantage of Hybrid System
• Use Bonded Assemblies Joints
• Provide Good Details on Connections

42
FRP - DESIGNHYBRID SYSTEMS

• High Strength in Composites
• High Stiffness in Conventional Materials
• Concrete Filled Carbon Shells
• Reinforced Timber Beams
• PS Tendons, Rods, Bars, Laminates
• Account for Material Compatibility

43
FRP - DESIGN FEATURES

• Avoid Abrupt Thickness Change
• Take Advantage of Geometric Shapes
• Take Advantage of Hybrid System
• Use Bonded Assemblies Joints
• Provide Good Details on Connections

44
FRP - DESIGNBONDED JOINTS

• Epoxy Bonded Assemblies
• Epoxy Bonded Joints
• Bonded Shear Transfer Strips
• Plate Bonding Technology
• Bonded Splices
• Durability of Joints

45
FRP - DESIGN FEATURES

• Avoid Abrupt Thickness Change
• Take Advantage of Geometric Shapes
• Take Advantage of Hybrid System
• Use Bonded Assemblies Joints
• Provide Good Details on Connections

46
FRP - DESIGNCONNECTION DETAILS

• Local Stress Flow
• Overall Load Path
• Weak Links
• Manufacturing Defects
• Fabrication Irregularities
• Select Proper Fasteners

47
FRP TECHNOLOGYFUTURE DEVELOPMENTS

• T2 from Aerospace Industry - CE transition
• Bridge structures - Stiffness Driven
• Customized vs. Open Market
• Cross Cutting Team in Design-Build
• Education and Training of SE/CEs
• New Construction Technology
• New Manuf./Fabric. Technology

48
FRP TECHNOLOGYCONCLUSION - 1

• Continue R D Activities
• Training
• Government Private Funding
• Building Teamwork Partnership
• Proprietary Products Patents
• Performance/Prescriptive Specs - Birth
  Certificate Baseline Reference

49
FRP TECHOLOGYCONCLUSION - 2

• AASHTO, ASCE, ACI, PCI,
• NSF, NIST (ATP), ISCC
• Euro and Japanese Standards (Std.)
• Design Std., Specs Guidelines
• Materials Specifications Testing Std.
• Manufacturing Process Standards
• Database Management