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HISTORY - FRP Fiber Reinforced Materials

HISTORY - FRP Fiber Reinforced Materials. Straw in Clay (Brick, Roof, Walls) Glass Fibers in Concrete Glass Fibers in Polymer. HISTORY - FRP POST WW-II APPLICATIONS. Boat Hulls Radomes Minesweeping Vessels Bath Tubs Covers. HS, CR, LW - New Developments

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HISTORY - FRP Fiber Reinforced Materials

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  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)

  18. 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 > 1.0) (Cured by Heat) • Novolac - Acidic (F/P < 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

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