DOT-Federal Highway Administration HISTORY - FRP Fiber Reinforced Materials n Straw in Clay (Brick, Roof, Walls) n Glass Fibers in Concrete n Glass Fibers

DOT-Federal Highway Administration

HISTORY - FRPHISTORY - FRPFiber Reinforced MaterialsFiber Reinforced Materials

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


HISTORY - FRPHISTORY - FRPPOST WW-II APPLICATIONSPOST WW-II APPLICATIONS

Boat Hulls Boat Hulls RadomesRadomes Minesweeping VesselsMinesweeping Vessels Bath TubsBath Tubs CoversCovers

HS, CR, LW - New Developments in Filament Winding and Pultrusion


HISTORY - FRPHISTORY - FRPPOST WW-II APPLICATIONS-2POST WW-II APPLICATIONS-2

Pressure VesselsPressure Vessels Submarine PartsSubmarine Parts Rocket ShellsRocket Shells Aircraft ComponentsAircraft Components Automobile Bodies & PartsAutomobile Bodies & Parts


HISTORY - FRPHISTORY - FRPPOST WW-II DOMESTIC APPLICATIONSPOST WW-II DOMESTIC APPLICATIONS

Bath TubsBath Tubs CoversCovers RailingsRailings Housing ComponentsHousing Components Architectural ComponentsArchitectural Components LaddersLadders Electrical EquipmentElectrical Equipment


HISTORY - FRPHISTORY - FRPPOST WW-II RECREATIONAL USESPOST WW-II RECREATIONAL USES

Fishing RodsFishing Rods Tennis RacketsTennis Rackets Ski EquipmentSki Equipment Golf ClubsGolf Clubs Recreation BoatsRecreation Boats SkatesSkates


FRP CONSUMPTIONFRP CONSUMPTION(IN MILLION POUNDS)(IN MILLION POUNDS)

INDUSTRY 1996 1997 1998 Aircraft 23.7 23.9 24.2 Appliance/Bus Equip 176.9 186.0 189.3 Construction 655.1 699.6 735.5 Consumer 194.2 210.0 218.6 Corrosion Resistant 381.1 396.0 374.9 Electrical/Electronic 318.8 348.2 348.2 Marine 367.9 353.0 353.0 Transportation 998.5 1095.2 1135.4 Other 107.3 110.8 114.9

TOTAL 3223.5 3421.7 3494.0

Source: SPI CI, April 99


FRP - CIVIL STRUCTURESFRP - CIVIL STRUCTURESCURRENT FIELD ACTIVITIESCURRENT FIELD ACTIVITIES

Pedestrian BridgesPedestrian Bridges Highway BridgesHighway Bridges Seismic Retrofit ColumnsSeismic Retrofit Columns Bridge StrengtheningBridge Strengthening Bridge RepairsBridge Repairs


FRP TECHNOLOGYFRP TECHNOLOGYCHARACTERISTICSCHARACTERISTICS

High StrengthHigh Strength High Resistance to Corrosion and ChemicalHigh Resistance to Corrosion and Chemical High Resistance to Elevated TemperatureHigh Resistance to Elevated Temperature High Resistance to AbrasionHigh Resistance to Abrasion ToughnessToughness FatigueFatigue Light WeightLight Weight


FRP TECHNOLOGYFRP TECHNOLOGYADVANTAGESADVANTAGES

Ease in Fabrication, Manufacturing, Ease in Fabrication, Manufacturing, Handling, and ErectionHandling, and Erection

Year-Round ConstructionYear-Round Construction Short Project Time DeliveryShort Project Time Delivery High PerformanceHigh Performance Durability (Jury Still Out)Durability (Jury Still Out) Excellent Strength-to-Weight Ratio Excellent Strength-to-Weight Ratio


FRP TECHNOLOGYFRP TECHNOLOGYDISADVANTAGES -1DISADVANTAGES -1

High First CostHigh First Cost Creep and ShrinkageCreep and Shrinkage Potential for Environmental Degradation Potential for Environmental Degradation

(Alkalis’ Attack, UV Radiation Exposure, (Alkalis’ Attack, UV Radiation Exposure, Moisture Absorption, etc.)Moisture Absorption, etc.)

Consistency of Material PropertiesConsistency of Material Properties


FRP TECHNOLOGYFRP TECHNOLOGYDISADVANTAGES - 2DISADVANTAGES - 2

Global and Local BucklingGlobal and Local Buckling Aerodynamic Instability With LightweightAerodynamic Instability With Lightweight Requires Highly Trained SpecialistsRequires Highly Trained Specialists Lack of Standards and Design GuidesLack of Standards and Design Guides Limited Joining and Connection Limited Joining and Connection

Technology (Adhesive joints, fasteners)Technology (Adhesive joints, fasteners)


FRP TECHNOLOGYFRP TECHNOLOGYPUBLIC CONCERNSPUBLIC CONCERNS

Fire/Flame ResistanceFire/Flame Resistance Smoke ToxicitySmoke Toxicity Fuel SpillsFuel Spills Vandalism/TheftVandalism/Theft InspectibilityInspectibility RepairabilityRepairability


MANUFACTURING PROCESSMANUFACTURING PROCESSCOMMON TO CIVIL APPLICATIONSCOMMON TO CIVIL APPLICATIONS

PultrusionPultrusion Filament WindingFilament Winding LayupLayup


WHAT IS FRP COMPOSITESWHAT IS FRP COMPOSITESCOMPONENTSCOMPONENTS

Fiber ReinforcementFiber Reinforcement Resin MatrixResin Matrix

***(Fiber-Matrix Interphases)******(Fiber-Matrix Interphases)*** FillersFillers AdditivesAdditives


FRP TECHNOLOGYFRP TECHNOLOGYMECHANICAL PROPERTIESMECHANICAL PROPERTIES

Fiber TypesFiber Types Fiber OrientationsFiber Orientations Fiber ArchitectureFiber Architecture Fiber Volume (30-70%)Fiber Volume (30-70%)


FRP TECHNOLOGYFRP TECHNOLOGYFIBER TYPESFIBER TYPES

GlassGlass AramidAramid Carbon (Graphite)Carbon (Graphite) BoronBoron Polyvinyl alcohol (PVA) Polyvinyl alcohol (PVA) (Available in Japan)(Available in Japan)


FRP TECHNOLOGYFRP TECHNOLOGYFIBER OREIENTATIONFIBER OREIENTATION

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


FRP TECHNOLOGYFRP TECHNOLOGYFIBER ARCHITECTUREFIBER ARCHITECTURE

Braiding (2D & 3D)Braiding (2D & 3D) KnittingKnitting WeavingWeaving StitchedStitched ChoppedChopped


FRP TECHNOLOGYFRP TECHNOLOGYCARBON FIBERCARBON FIBER

Three Polymer Precursors: Three Polymer Precursors: *Polyacrylonitrile (PAN) *Polyacrylonitrile (PAN) *Rayon *Rayon *Pitch*Pitch

Anisotropic MaterialsAnisotropic Materials Linear Elastic to FailureLinear Elastic to Failure Failure by RuptureFailure by Rupture


FRP TECHNOLOGYFRP TECHNOLOGYARAMID FIBERARAMID FIBER

Aromatic PolyamidesAromatic Polyamides Kevlar 29Kevlar 29 Kevlar 49Kevlar 49 Anisotropic MaterialsAnisotropic Materials Linear Elastic to FailureLinear Elastic to Failure Failure by RaptureFailure by Rapture


FRP -TYPICAL PROPERTIESFRP -TYPICAL PROPERTIES

FIBER STRENGTH (KSI)

MODULUS(MSI)

STRAIN(%)

E-Glass 350 6 2S-Glass 500 6 3CF-Pan 600 33-50 2C-Pitch GP 200 6 0.3Pitch UHM 400 70-120 0.5Aramid 500 10-20 2Ceramic 100 10-40 2Nylon 50 0.5 5-50

Source: Tonen Energy Corp


FRP BRIDGE FRP BRIDGE TECHNOLOGYTECHNOLOGY

FIBER PROPERTIESFIBER PROPERTIES

fibe

r st

ress

(G

pa)

fiber strain (%)

1

2

3

4

1 2 3 4

E-glass (350 ksi)

Aramid (500 ksi)

Carbon (600 ksi)


FRP TECHNOLOGYFRP TECHNOLOGYRESIN SYSTEMRESIN SYSTEM

ThermoplasticsThermoplastics (melts when heated, solidifies when cooled, no (melts when heated, solidifies when cooled, no permanent curing)permanent curing)

ThermosetsThermosets (cures permanently by irreversible cross linking at (cures permanently by irreversible cross linking at elevated temp.)elevated temp.)


FRP TECHNOLOGYFRP TECHNOLOGYRESIN FORMULATIONSRESIN FORMULATIONS

ViscosityViscosity ReactivityReactivity ResiliencyResiliency High Deflection Temperature (HDT)High Deflection Temperature (HDT)


FRP TECHNOLOGYFRP TECHNOLOGYRESIN TYPESRESIN TYPES

Unsaturated PolyestersUnsaturated Polyesters EpoxiesEpoxies Vinyl EstersVinyl Esters PolyurethanesPolyurethanes PhenolicsPhenolics


FRP - RESIN SYSTEMFRP - RESIN SYSTEMUNSATURATED POLYESTERS - 1UNSATURATED POLYESTERS - 1

75% Resins Used in USA75% Resins Used in USA Condensation Polymerization of Condensation Polymerization of

Dicarboxylic Acids & Dihydric AlcoholsDicarboxylic Acids & Dihydric Alcohols Contains Maleic Anhydride or Contains Maleic Anhydride or

Fumaric Acid Fumaric Acid


FRP - RESIN SYSTEMFRP - RESIN SYSTEMUNSATURATED POLYESTERS - 2UNSATURATED POLYESTERS - 2

Dimensional StabilityDimensional Stability Affordable CostAffordable Cost Ease in Handling, Processing, & Ease in Handling, Processing, &

ManufacturingManufacturing High Corrosion Resistant & Fire RetardantsHigh Corrosion Resistant & Fire Retardants Best Value for Performance & StrengthBest Value for Performance & Strength


FRP - RESIN SYSTEMFRP - RESIN SYSTEMEPOXIESEPOXIES Glycidyl Ethers and AminesGlycidyl Ethers and Amines Customized PropertiesCustomized Properties Limited WorkabilityLimited Workability Sensitive to Curing AgentsSensitive to Curing Agents High PerformanceHigh Performance High First CostHigh First Cost


FRP - RESIN SYSTEMFRP - RESIN SYSTEMVINYL ESTERSVINYL ESTERS

Good WorkabilityGood Workability Fast CuringFast Curing High PerformanceHigh Performance ToughnessToughness Excellent Corrosion ResistanceExcellent Corrosion Resistance


FRP - RESIN SYSTEMFRP - RESIN SYSTEMPOLYURETHANESPOLYURETHANES

Polyisocyanate & PolyolPolyisocyanate & Polyol Reaction or Reinforced Injection Molding Reaction or Reinforced Injection Molding

ProcessProcess High PerformanceHigh Performance ToughnessToughness Excellent Corrosion ResistenceExcellent Corrosion Resistence


FRP - RESIN SYSTEM FRP - RESIN SYSTEM PHENOLICSPHENOLICS Phenols & FormaldehydePhenols & Formaldehyde Resole - Alkaline (F/P > 1.0) Resole - Alkaline (F/P > 1.0)

(Cured by Heat)(Cured by Heat) Novolac - Acidic (F/P < 1.0)Novolac - Acidic (F/P < 1.0)

(Cured by Chemical Reaction)(Cured by Chemical Reaction) Resistance to High TemperatureResistance to High Temperature Good Thermal StabilityGood Thermal Stability Low Smoke Generation Low Smoke Generation


FRP TECHNOLOGY FRP TECHNOLOGY FILLERSFILLERS

Control Composites’ CostControl Composites’ Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep & ShrinkageReduced Creep & Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant & Chemical ResistantFire Retardant & Chemical Resistant


FRP TECHNOLOGYFRP TECHNOLOGYFILLER TYPESFILLER TYPES

Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica, Talc, GlassSilica, Talc, Glass


FRP TECHNOLOGYFRP TECHNOLOGYADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance


FRP TECHNOLOGYFRP TECHNOLOGYADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents


FRP TECHNOLOGYFRP TECHNOLOGYSMART MATERIALSSMART MATERIALS

Innovative Design Innovative Design and Applicationand Application

Customized Product Customized Product for for High PerformanceHigh Performance

VersatilityVersatility Complex Design ProcessComplex Design Process Materials, Processing, ConfigurationsMaterials, Processing, Configurations


FRP - DESIGN FEATURESFRP - DESIGN FEATURES

Avoid Abrupt Thickness ChangeAvoid Abrupt Thickness Change Take Advantage of Geometric ShapesTake Advantage of Geometric Shapes Take Advantage of Hybrid SystemTake Advantage of Hybrid System Use Bonded Assemblies & JointsUse Bonded Assemblies & Joints Provide Good Details on ConnectionsProvide Good Details on Connections


FRP - DESIGNFRP - DESIGNAVOID ABRUPT THICKNESSAVOID ABRUPT THICKNESS

Inefficient By ThicknessInefficient By Thickness Avoid Stress RisersAvoid Stress Risers Consider Stress FlowConsider Stress Flow Consider Load PathsConsider Load Paths Understand Structural BehaviorUnderstand Structural Behavior





FRP - DESIGNFRP - DESIGNGEOMETRICAL SHAPESGEOMETRICAL SHAPES

Low StressesLow Stresses Optimize Design - Balance CriteriaOptimize Design - Balance Criteria

(Stress, Deflection, and Stability)(Stress, Deflection, and Stability) Use Flanges, Ribs, StiffenersUse Flanges, Ribs, Stiffeners Use Honeycomb or Box Cells, TubesUse Honeycomb or Box Cells, Tubes Proportioning and Orienting CellsProportioning and Orienting Cells





FRP - DESIGNFRP - DESIGNHYBRID SYSTEMSHYBRID SYSTEMS

High Strength in CompositesHigh Strength in Composites High Stiffness in Conventional MaterialsHigh Stiffness in Conventional Materials Concrete Filled Carbon ShellsConcrete Filled Carbon Shells Reinforced Timber BeamsReinforced Timber Beams PS Tendons, Rods, Bars, LaminatesPS Tendons, Rods, Bars, Laminates Account for Material CompatibilityAccount for Material Compatibility





FRP - DESIGNFRP - DESIGNBONDED JOINTSBONDED JOINTS

Epoxy Bonded AssembliesEpoxy Bonded Assemblies Epoxy Bonded JointsEpoxy Bonded Joints Bonded Shear Transfer StripsBonded Shear Transfer Strips Plate Bonding TechnologyPlate Bonding Technology Bonded SplicesBonded Splices Durability of JointsDurability of Joints





FRP - DESIGNFRP - DESIGNCONNECTION DETAILSCONNECTION DETAILS

Local Stress FlowLocal Stress Flow Overall Load PathOverall Load Path Weak LinksWeak Links Manufacturing DefectsManufacturing Defects Fabrication IrregularitiesFabrication Irregularities Select Proper FastenersSelect Proper Fasteners


FRP TECHNOLOGYFRP TECHNOLOGYFUTURE DEVELOPMENTSFUTURE DEVELOPMENTS

TT22 from Aerospace Industry - CE transition from Aerospace Industry - CE transition Bridge structures - Stiffness DrivenBridge structures - Stiffness Driven Customized vs. Open MarketCustomized vs. Open Market Cross Cutting Team in Design-BuildCross Cutting Team in Design-Build Education and Training of SE/CEsEducation and Training of SE/CEs New Construction TechnologyNew Construction Technology New Manuf./Fabric. TechnologyNew Manuf./Fabric. Technology


FRP TECHNOLOGYFRP TECHNOLOGYCONCLUSION - 1CONCLUSION - 1

Continue R & D ActivitiesContinue R & D Activities TrainingTraining Government & Private FundingGovernment & Private Funding Building Teamwork & PartnershipBuilding Teamwork & Partnership Proprietary Products & PatentsProprietary Products & Patents Performance/Prescriptive Specs - “Birth Performance/Prescriptive Specs - “Birth

Certificate” & Baseline ReferenceCertificate” & Baseline Reference


FRP TECHOLOGYFRP TECHOLOGYCONCLUSION - 2CONCLUSION - 2

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

Documents

DOT-Federal Highway Administration HISTORY - FRP Fiber Reinforced Materials n Straw in Clay (Brick, Roof, Walls) n Glass Fibers in Concrete n Glass Fibers