The use of prestressed

CFRP-Laminates
as post-strengthening
Gregor SCHWEGLER
PlssMeyerPartner AG
Luzern, Switzerland
Thierry BERSET
ETH Zrich
Zrich, Switzerland
Paper presented at the 16
th
Congress of IABSE
September 18-21, Luzern, Switzerland
The use of prestressed CFRP-Laminates as post-strengthening
Gregor SCHWEGLER
Dr. sc. techn.
dipl. Ing. ETH
PlssMeyerPartner AG
Luzern, Switzerland
Gregor Schwegler, born 1963,
received his civil engineering
degree from the ETH Zurich in
1990. His PhD was conferred on
him in 1994 by the same
university and the EMPA
Thierry BERSET
dipl. Ing. ETH
Institute of Structural
Engineering, ETH Zurich
Zurich, Switzerland
Thierry Berset, born 1973,
received his civil engineering
degree from the ETH Zurich
in1998
Summary
This article describes the use of prestressed externally glued Carbon Fibre Reinforced Plastic
(CFRP) - laminates as post-strengthening of existing structures. The advantages of CFRP-laminates
compared to steel are discussed. Prestressing the CFRP-laminates results in varying positive effects
on the strengthened section and allows to increase the utilisation factor of the high tensile strength
of CFRP. Asystem for prestressing and anchoring CFRP-laminates under on-site conditions is
presented. Aseries of laboratory tests was carried out. As a first test-application a transverse girder
of a highway bridge was strengthened by a prestressed CFRP-plate.
Keywords: Carbon Fibre Reinforced Plastics, CFRP-laminates, Prestressing, post-strengthening
1. Introduction
There exist many structures such as bridges, storage-buildings or parking-decks with a insufficient
bending resistance that have to be replaced or reinforced. The reason can be a change in use, new
standards, changes in the structure itself due to conversion, ageing (corrosion and fatigue), damage
(impact or fire) or mistake in design or realisation. In many of these cases strengthening allows the
reuse of major parts of the existing structure instead of a complete replacement. Prestressed Carbon
Fibre Reinforced Plastic (CFRP) - laminates offer new possibilities for reinforcing existing
structures.
Externally bonded steel plates are used successfully for reinforcing since more than 30 years. Long
term studies on weather exposed beams with external steel-plate reinforcement showed that
corrosion below the steel plates appears even without the influence of thawing salt. Also fatigue due
to friction in the zone of cracks in the concrete can be a problem. On the other hand, CFRP-
laminates are non corroding in most environmental conditions and fatigue is normally no problem.
Another disadvantage of steel plates is their heavy weight which complicates the handling on site.
By contrast, CFRP-laminates are extremely light weight and can be delivered on coils in lengths up
to 300 m or more. They can be glued without the necessity of a temporary fixation.
Amajor disadvantage of CFRP-laminates was until recently the high cost of the material. But it is
to be expected that the cost of CFRP will decrease to a level that is not higher than that of steel, if
the tensile strength is compared. Considering the easy application and the excellent durability, the
overall cost of a CFRP-strengthening is already now cheaper than strengthening with steel plates.
2. The effect of prestressing
Prestressing the CFRP results in later yielding of the internal steel reinforcement and a higher
bending resistance. The cost of prestressing can partially be compensated by a reduction of the
number of CFRP-laminates.
Prestressed CFRP-laminates decrease the stress of the internal steel reinforcement even under dead
loads. This results in a reduced deflection and overall crack width. Agood crack distribution results
from the stiff bond between CFRP and concrete. These effects increase the durability and improve
the fatigue behaviour.
In most cases the utilisation factor of the tensile strength of the CFRP is limited to a low level
because delamination between CFRP and concrete at the rim of shear cracks appears. Prestressing
results in a reduction of the displacement of the rims of shear cracks and therefore reduces the
danger of delamination.
The main problem of prestressing CFRP-laminates is how to anchor the high tensile force at the end
of the CFRP-plate. The ultimate shear stress between CFRP and concrete is too low and has a wide
range that is influenced mainly by the material properties of the concrete and the crack distribution.
3. The Prestressing System
The presented prestressing system is based on the idea to anchor the end of the CFRP-plate in a
non-metallic "StressHead" that lasts permanently on or in the strengthened structure.
Preparation of the surface of the concrete and application of Epoxy adhesive to CFRP-laminates
and concrete is done in the same way as for unstresed CFRP-laminates.
One part of the "StressHead" is anchored to the
concrete while the other is connected to the CFRP-
laminates under controlled conditions. The
compact dimensions of "StressHead" (length
width height = 99mm 72mm 56mm) allow a
wide range of applications. Prestressing the CFRP
is done by a hydraulic press. Then "StressHead" is
fixed in its final position and the prestressing
equipment can be removed.
All parts of "StressHead" that remain permanently
on the strengthened structure are made of CFRP, so
the system has the same durability as the CFRP-
laminates. Aprototype of a anchor can be seen in
Fig. 1. On the right, the prestressed CFRP-plate
leaves the "StressHead". The straps on the left are
just used to fix the StressHead in the testing
machine. The CFRP-laminates are prestressed to
about
P0
= 1500 N/mm
2
with a CFRP-plate of 60mm 2.4mm. It is planned to increase the
dimension of the prestressed CFRP plate and to achieve a prestressing force of up to 500 kN.
4. Laboratory testing
The development a anchor for prestressing CFRP-laminates started in 1995. First prototypes were
made of steel and aluminium because these materials, in contrary to CFRP, allow a easy variation of
the geometry. Aseries of eight StressHeads of four different types was tested in 1999. It was
possible to anchor CFRP-laminates of 80mm 2.4mm up to their tensile strength. The next step
was achieved by the end of 1999 with the first tests on anchors made completely of CFRP.
5. On site application
As a first test application a transverse girder of a highway bridge was strengthened with a
prestressed CFRP-plate in 1999. The CFRP-plate served as a temporary external prestressing of a
existing bridge deck during construction time. This offered the opportunity to test the prestressing
system "StressHead" under on site conditions and to inspect the complete in the course of the
demoliton.
AStressHead made of steel and aluminium as it was tested at the beginning of 1999 was used for
this application. There was no danger of corrosion because the prestressing system was only used
for a few months. Prestressing was controlled with two strain gauges on each CFRP-plate and by
the pressure of the hydraulic press. The strain of the CFRP-laminates was controlled about seven
months after prestressing. There was no significant loss of strain in the CFRP.
Fig. 1 Prototype of StressHead
The use of prestressed CFRP-Laminates as post-strengthening
Gregor SCHWEGLER
Dr. sc. techn.
dipl. Ing. ETH
PlssMeyerPartner AG
Luzern, Switzerland
Gregor Schwegler, born 1963,
received his civil engineering
degree from the ETH Zurich in
1990. His PhD was conferred on
him in 1994 by the same
university and the EMPA
Thierry BERSET
dipl. Ing. ETH
Institute of Structural
Engineering, ETH Zurich
Zurich, Switzerland
Thierry Berset, born 1973,
received his civil engineering
degree from the ETH Zurich
in1998
Summary
This article describes the use of prestressed externally glued Carbon Fibre Reinforced Plastic
(CFRP) - laminates as post-strengthening of existing structures. The advantages of CFRP-laminates
compared to steel are discussed. Prestressing the CFRP-laminates results in varying positive effects
on the strengthened section and allows to increase the utilisation factor of the high tensile strength
of CFRP. Asystem for prestressing and anchoring CFRP-laminates under on-site conditions is
presented. Aseries of laboratory tests was carried out. As a first test-application a transverse girder
of a highway bridge was strengthened by a prestressed CFRP-plate.
Keywords: Carbon Fibre Reinforced Plastics, CFRP-laminates, Prestressing, post-strengthening
1. Introduction
There exist many structures such as bridges, storage-buildings or parking-decks with a insufficient
bending resistance that have to be replaced or reinforced. The reason can be a change in use, new
standards, changes in the structure itself due to conversion, ageing (corrosion and fatigue), damage
(impact or fire) or mistake in design or realisation. In many of these cases strengthening allows the
reuse of major parts of the existing structure instead of a complete replacement. Prestressed Carbon
Fibre Reinforced Plastic (CFRP) - laminates offer new possibilities for reinforcing existing
structures.
Externally bonded steel plates are used successfully for reinforcing since more than 30 years. Long
term studies on weather exposed beams with external steel-plate reinforcement showed that
corrosion below the steel plates appears even without the influence of thawing salt [1 and 2]. Under
harder environmental conditions, such as the strengthening of highway bridges with extensive use
of thawing salt, corrosion of the steel plates is a serious problem. Mainly because of this reason the
technology of strengthening concrete beams by externally bonded CFRP-laminates was developed
at the EMPAsince 1985 [3]. CFRP-laminates are non-corroding in most environmental conditions,
especially in the alkaline environment on a concrete surface [4].
In contrast to steel plates, where fatigue due to friction in the zone of cracks in the concrete can be a
problem, fatigue is normally no problem for CFRP-laminates. ACFRP-plate is a composite material
which consists of millions of carbon fibres that are only connected by the epoxy resin. Crack
growing as in steel is therefore impossible, even if a single carbon fibre is extremely brittle.
Another disadvantage of steel plates compared to CFRP-plates is their heavy weight which
complicates the handling on site. The need to carry steel plates by hand restricts the length to about
6-8 m. Joints are realised with glued single shear lap joints. The steel plates have to be hold in
position by dowels or another fixing system until the adhesive is hardened. Crossings of plates are
very expensive to realise. Normally, the thickness of one plate is doubled except in the zone of the
crossing, where a recess is arranged to offer place for the crossing plate. By contrast, CFRP-
laminates are extremely light weight and can be delivered on coils in lengths up to 300 m or more.
Thanks to the light weight, CFRP-laminates can be glued without the necessity of a temporary
fixation. They are just pressed on the concrete surface. Crossings can be realised without any
special measures due to the thin CFRP-laminates that result from the very high strength of the
material.
Amajor disadvantage of CFRP-laminates was until recently the high cost of the material. The cost
per kg of CFRP-laminates is about 100 times higher than that of ordinary steel. But they have a very
high tensile strength and a low specific gravity. This is why the cost of CFRP is only about two
times higher than that of steel if the tensile strength is compared (Table 1). If the very simple
application of CFRP-laminates is also considered, the overall cost of a CFRP-reinforcing is already
now cheaper than strengthening with steel plates. The excellent durability of CFRP-laminates
results in very low long term cost compared to steel.
Table 1 Comparison steel-plates - CFRP-laminates
steel plates CFRP-laminates
developed since 1967
in use since 1970
30 years experience
developed since 1985
in use since 1994
5 years experience
Mechanical properties and cost
Price k = 2 CHF/kg k = 220 CHF/kg
Tensile strength f
y
= 235 MPa f
t
= 3000 MPa
Modulus of elasticity E = 210'000 MPa E = 170'000 MPa
specific gravity = 8000 kg/m
3
= 1600 kg/m3
specific tensile strength f
y
/ = 30 kNm/kg f
t
/ = 1900 kNm/kg
specific modulus of
elasticity
E / = 26 MNm/kg E / = 120 MNm/kg
strength / cost
1
f
y
/ (k)
=
15 kNm/CHF f
t
/ (k) = 8.5 kNm/CHF
stiffness / cost
2
E / (k) = 13 MNm/CHF E / (k) = 0.5 MNm/CHF
Application
Application expensive
temporary fixation, sometimes crane
simple and cheap
no fixation, just roll to the surface
Length of a unit 6...8m (weight, handling)
joints necessary
coils up to 300m length
Crossings expensive very simple
Aesthetics steel plates are thick CFRP laminates are very thin
practically invisible
Durability
Corrosion between steel and glue
de-icing salts cause problems
no corrosion under practically all
environmental conditions
Fatigue fatigue due to friction at cracks no fatigue
1
The unit 1 kNm/CHF means, that for the cost of 1 CHF a force of 1 kN can be transferred over
a length of 1 m
2
The unit 1 MNm/CHF means, that for the cost of 1 CHF at a strain of 1
0
/
00
a force of 1 kN is
transferred over a length of 1 m.
The cost of CFRP-laminates that is given in Table 1 is rather too high. It is to be expected that the
cost of CFRP will decrease to a level that is not higher than that of steel, if the tensile strength is
compared. The cost of CFRP to provide a certain stiffness however is very high compared to steel.
This disadvantage can be partially compensated by prestressing the CFRP in many cases.
The use of externally bonded CFRP-laminates for strengthening structures in concrete, masonry or
wood is nowadays a established and reasonable technology.
2. The effect of prestressing
As shown above, the cost of CFRP-laminates is not higher than that of steel if the tensile strength is
compared. The cost of CFRP-laminates to provide a certain stiffness however is about 25 times
higher than that of steel. There are many applications where the high tensile strength of CFRP can
not be used due to a lack of stiffness. CFRP-laminates with a higher stiffness (so called high-
modulus CFRP) are available, but they are very expensive and have a lower tensile strength. One
possible solution of this problem is to prestress the CFRP. The behaviour of RC-beams with a
strengthening consisting of prestressed CFRP-laminates is described in [5]. Prestressing the CFRP
results in a later yielding of the internal steel reinforcement and a higher bending resistance. In
many cases there is not enough place for a strengthening with unstressed CFRP-laminates. As
prestressing allows to make use of the high tensile strength of CFRP, the number of laminates can
be reduced. The cost of prestressing are partially compensated by the reduction of the number of
laminates.
Prestressed CFRP-laminates decrease the stress of the internal steel reinforcement even under dead
loads. This results in a reduced deflection and overall crack width. Agood crack distribution results
from the stiff bond between CFRP and concrete. The overall behaviour of the strengthened structure
under service loads is therefore improved.
The reduction of tensile stress of the internal steel reinforcement together with a better crack
distribution results in a improved fatigue resistance of the strengthened structure.
In most cases the utilisation factor of the high tensile strength of CFRP-laminates is limited because
bond failure between CFRP and concrete at the rim of shear cracks can appear before tension failure
of the CFRP. Prestressing the concrete results in a reduction of the displacement of the rims of shear
cracks and therefore allows to increase the admissible tensile stress in the CFRP.
The positive effect of externally bonded prestressed CFRP-laminates on the behaviour of the
strengthened structure is proven by calculation and testing. The CFRP-laminates should be
prestressed as high as possible. The main problem is how to anchor the high tensile force at the end
of the CFRP-plate. The ultimate shear stress between CFRP and concrete has a wide range and is
influenced mainly by the material properties of the concrete and the crack distribution. As already
mentioned, bond failure between CFRP and concrete limits the possible tensile stress in the CFRP
in most cases. Continuous bond failure ends in failure of the CFRP-plate. The necessary high
prestressing ratio can hardly be reached without a solution to anchor the end of the CFRP-plate.
3. The Prestressing System
The presented prestressing system that was used in laboratory tests and in test applications is based
on the idea to anchor the end of the CFRP-plate in a non-metallic "StressHead" that lasts
permanently on or in the strengthened structure. The connection between CFRP-laminates and
"StressHead" is assembled under controlled conditions. The range of the tensile resistance of this
connection can be reduced to a acceptable extent. The reliability is much better than that of a glued
connection between CFRP-plate and concrete, where the material properties of the concrete can not
be controlled.
The application of a prestressed CFRP-plate using this System is realised in the following steps:
1. Preparation of the concrete surface in the same way as for conventionally glued CFRP-
laminates
2. Connection of the CFRP-plate to the "StressHead". Mistakes in manipulation are prevented by
the design of the "StressHead". The connection will always reach the necessary resistance.
3. The "StressHead" is connected to the strengthened structure. The compact dimensions of the
"StressHead" (length width height = 99mm 72mm 56mm) allow to adapt this
connection to many situations.
4. Application of the epoxy adhesive to the CFRP-plate and the concrete surface in the same way
as for conventional strengthening with CFRP-laminates.
5. Pre-stressing the CFRP-plate by a hydraulic press. Force and displacement are controlled during
pre-stressing action. The "StressHead" is fixed in its final position and the prestressing
equipment can be removed.
6. The CFRP laminates are pressed to the concrete in the same way as unstressed CFRP-laminates.
All parts of the "StressHead" that remain permanently on the strengthened structure are made of
CFRP. The whole system has the same durability as the CFRP-laminates. Aprototype of this
StressHead as it was tested at the end of 1999 can be seen in Fig. 1. On the right, the prestressed
CFRP-plate leaves the StressHead. The
straps on the left are just used to fix the
StressHead in the testing machine and
are not part of the StressHead used in a
application. The CFRP-laminates are
prestressed to about
P0
= 1500 N/mm
2
which is equivalent to a pre-stressing
ratio of about 50 - 60% of the tensile
strength. The first prototypes are able
to prestress a CFRP-plate of 60mm
2.4mm. The prestressing force is
therefore about 220 kN. It is planned to
increase the dimension of the pre-
stressed CFRP plate and to anchor a
prestressing force of up to 500 kN.
Fig. 1 Prototype of a "StressHead"
4. Laboratory testing
The development of a anchor for prestressing CFRP-laminates started in 1995. The need for a
reliable and compact end anchor for CFRP-laminates came up during the research work on CFRP-
strengthened masonry [6]. Laboratory tests with
prototypes made of steel were carried out from
1996 to 1999. Steel and aluminium were chosen
because these materials, in contrary to CFRP,
allow a easy variation of the geometry of
prototypes. Aseries of eight StressHeads of four
different types was tested in 1999. It was possible
to anchor CFRP-laminates of 80mm 2.4mm up
to their tensile strength. One example of a tension
- strain - diagram is given in Fig. 2. The nominal
tensile strength of the CFRP-plate used in this test
was 2800 N/mm
2
. Rupture was observed outside
the anchor at a stress of 2900 N/mm
2
. The next
step was achieved by the end of 1999 with the first
tests on anchors made completely of CFRP. These
anchors have the same durability as the CFRP-
laminates (Fig. 1).
5. On site application
As a first test application a cross girder of a highway bridge was strengthened with a prestressed
CFRP-plate in 1999 (Fig. 3). The bridge crosses the river Reuss in the canton Uri with three spans.
0
500
1000
1500
2000
2500
3000
0 5 10 15 20
Typ 3

[
N
/
m
m
2
]
[
0
/
00
]
Fig. 3 Reussbrcke N4
Fig. 2 Example of a tension - strain diagram of a StressHead made of steel
The cross section consists of two traffic lanes and a sidewalk. The existing bridge was built of five
prestressed precast concrete beams and a precast deck with a in situ concrete covering. The main
beams are connected by nine transverse girders. Shearing resistance was insufficient at the joints of
the main beams in the mid-span. The thin precast concrete elements of the deck are also insufficient
for actual load cases, especially for wheel pressures. Concrete cover of reinforcement and tendons
was insufficient and corrosion appeared. Afirst study showed that strengthening and repair of the
existing bridge deck would cost about as much as a replacement by a new steel-concrete composite
deck.
One traffic lane had to be provided during construction time without interruption. As the bridge
access is on a dam on both sides of the bridge, a temporary bridge was too expensive to be realised.
As first step, one side of the existing bridge was demolished. The new bridge deck was constructed
in a displaced position (on the left in Fig. 4) while the rest of the old bridge served as traffic lane
(on the right in Fig. 4). In a next phase, the rest of the existing bridge was demolished and the new
bridge deck was pulled to its final position.
Fig. 4 Cross section during the construction of the new bridge deck
In the course of the demolition of the first half of the existing bridge, the prestressed concrete cross
girders had to be cut. There was no continuous reinforcement in the cross girders except of the
tendons. The tendons are placed in flat-surfaced plastic ducts and therefore loose a significant
amount of prestressing when cut. It was necessary to replace these internal tendons by a external
prestressed steel ties before cutting the cross girders in order to provide load distribution and the
stabilisation of the main beams. Eight of the nine cross girders were strengthened by external pre-
stressed steel bars. One cross girder was prestressed by a CFRP-plate. This offered the possibility to
test the prestressing system "StressHead" under on site conditions and to inspect the complete
system before and after demolition of the second half of the bridge.
AStressHead made of steel and aluminium as it was tested at the beginning of 1999 was used for
this application. There was no danger of corrosion because the prestressing system was only used
for a few months. The CFRP-laminates are arranged in the form of a loop around the transverse
beam as shown in Fig. 5. Both StressHeads in the middle of the bridge are supported by the same
steel plate. This guaranties a equivalent distribution of the prestressing force to both CFRP-
laminates. The loop on the outer side of the bridge is formed by a steel saddle.
Prestressing was controlled with two strain gauges on each CFRP-plate and by the pressure of the
hydraulic press.
Fig. 5 Ground plan and sectional view of the arrangement of the CFRP-laminates
The strain of the CFRP-laminates was controlled just before demolition of the second part of the
existing bridge about seven months after prestressing. There was no significant loss of stress in the
CFRP.
6. Conclusion
The use of CFRP-laminates is a efficient method for post-strengthening existing structures.
Prestressed CFRP-laminates are in many cases superior to other strengthening methods in economy,
quality and durability. The main advantage of the presented prestressing system is that it is based on
a simple anchor for CFRP-plates that is made completely of CFRP. This anchor could also be used
for other applications such as no-bond prestressing.
7. Literature
[1] LADNER, M., PRALONG, J. and WEDER, CH., Geklebte Bewehrung: Bemessung und
Erfahrungen, EMPA Bericht Nr. 116/5, Eidgenssische Materialprfungs- und
Forschungsanstalt, EMPA, April 1990
[2] EGGER, G. and CANTIENI, R., Fnfzehnjhrige Stahlbetonbalken mit aufgeklebter
Bewehrung, EMPA Bericht Nr. 150'582, Eidgenssische Materialprfungs- und
Forschungsanstalt, EMPA, September 1994
[3] KAISER, HP., Bewehren von Stahlbeton mit Kohlenstoffaserverstrkten Epoxidharzen, ETH
Dissertation Nr. 8918, Eidgenssische Materialprfungs- und Forschungsanstalt EMPA, 1989
[4] HANCOX, N.L. and MAYER, R.M., Design Data for Reinforced Plastics, A Guide for
Engineers and Designers, Chapman & Hall, London, 1994
[5] DEURING, M., Verstrken von Stahlbeton mit gespannten Faserverbundwerkstoffen, EMPA
Bericht Nr. 224, Eidgenssische Materialprfungs- und Forschungsanstalt, EMPA, 1993
[6] SCHWEGLER, G., Verstrken von Mauerwerk mit Hochleistungsfaserverbund-Werkstoffen,
ETH Dissertation Nr. 10672, EMPA-Bericht Nr. 229, Eidgenssiche Materialprfungs- und
Forschungsanstalt EMPA, 1994
[7] SCHWEGLER, G., Verstrkung von Mauerwerk mit CFK-Lamellen sowie CFK-
Verstrkungen im Mauerwerks- und Holzbau. Nachtrgliche Verstrkung von Bauwerken mit
CFK-Lamellen, EMPA/SIA-Studientagung. Schweizerischer Ingenieur- und Architekten-
Verein, Dokumentation D 0128, S.71-83 sowie S.61-65, 21. September 1995
[8] MEIER U., DEURING M., MEIER H. and SCHWEGLER G., Strengthening of Structures
with CFRP Laminates: Research and Applications in Switzerland, Advanced Composite
Materials in Bridges and Structures, Canadian Society for Civil Engineering, 1992, pp 243-
251
[9] MEIER U., Carbon Fiber-Reinforced Polymers: Modern Materials in Bridge Engineering.
Structural Engineering International No 1, 1992
[10] Nachtrgliche Verstrkung von Bauwerken mit CFK-Lamellen, EMPA/SIAStudientagung,
Schweizerischer Ingenieur- und Architekten- Verein, Dokumentation D 0128, 21. September
1995
[11] Verstrken von Tragwerken mit CFK-Lamellen, TFB Fachveranstaltung, Technische
Forschung und Beratung fr Zement und Beton, 12. Mai 1998