OTIA III State Bridge Delivery Program Management & Design

FIBERREINFORCEDPOLYMER(FRP)FLEXURAL
STRENGTHENINGDESIGNPROGRAM
USERMANUAL
Version1.21

Prepared by

1165 Union St., Suite 200

Salem, Oregon 97301

IssueDateMayJuly2006

Disclaimer
PortionsofthecontentsofthisdesignprogramweredevelopedcooperativelybyOregon
Department of Transportation (ODOT) and Oregon Bridge Delivery Partners (OBDP).
ODOTandOBDPassumenoliabilityorresponsibilityforandmakenorepresentationsor
warrantiesastoapplicabilityorsuitabilityofthisprogram.Anyonemakingusethereofor
relyingthereonassumesallresponsibilityandliabilityarisingfromsuchuseorreliance.

TABLEOFCONTENTS
Section1.....................Introduction
Section2.....................SoftwareDetailsandDiscussion
Section3.....................SoftwareUse

SECTION1

INTRODUCTION

Recentloadratingsrevealedthatmanyofthevintage1950sand1960sReinforcedConcrete
DeckGirder(RCDG)bridgesintheStateofOregonhavedeficientflexuralcapacity.Oneofthe
acceptablemethodstostrengthenthosegirders,whenthecontrollingflexuralloadratingsareno
lessthan0.85,isinstallingexternallybondedfiberreinforcedpolymer(FRP)stripsalongthe
girdersoffits. Thesestripsactasadditionallongitudinalreinforcement,subjecttothedesign
limitationsdescribedherein.
Fiberreinforcedpolymersaretypicallycomprisedofhighstrengthfibers(e.g.,carbon,glass)
impregnated with an epoxy, polyester, or vinyl ester resin. Currently, only carbon fiber
reinforced polymer (CFRP) is acceptable to ODOT. As more polymer types are approved,
revisionstotheODOTQPLwillbemade.SeveralprojectshavebeenrehabilitatedbyODOT
usingFRPtostrengthentheexistingreinforcedconcretebridgegirders,butthesehavetypically
beendesignedastemporaryrepairs. Thisdesignprocedureisdirectedatrehabilitationwitha
designlifeof25years.
Based on the design criteria recommended by ACI 440.2R02 and the technical memo,
ExternallyBondedFRPStrengtheningForOTIAIIIBridgeProgram(DRAFT),byOregon
Bridge Delivery Partners, OBDP developed a general FRP flexural strengthening design
softwareusingMathcadTM.
The purpose of this software is to help engineers convert girder moment demands from an
ODOTTier2LoadRating,LoadResistanceFactorRating(LRFR),intodesignloadsperODOT
BridgeDesignandDraftingManual(BDDM).Fromthis,theprogramassistsindeterminingthe
requiredFRPstripsize.Itshouldbenoted,however,that,insomecases,FRPrehabmaynotbe
suitable.Tousethisdesignsoftwarewithoutmodifications,thebridgeshouldbesuccessfully
loadratedbasedonODOTLRFRInterimScopingLoadRatingGuidelines,hereafterreferredto
asLRFRScopingRating.
Theproceduresstatedinthismanualaretoexplainthemethodologyusedinthissoftware,which
isconsistentwithBDDMandACI440.2R02.
Alistofthefilesthatareincludedinthedesignsoftwarepackageisgivenbelow:
FRP_Flexure_Design.MCD...............March27July26,2006.
ThesampleLRFRScopingRatingfiles(EXTGIR.DATandEXTGIR.OUTforBR.#00933)are
alsoincludedinthedesignsoftwarepackagefortheusersreference.
Themanualissubdividedintosectionstoallowforeasydocumentationoffuturemodifications.

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SECTION2

SOFTWAREDETAILSANDDISCUSSION

MathcadTM was selected as the software to develop the FRP flexural strengthening design
package.ThisdecisionwasdrivenbythefactthatthesamesoftwareisusedinLRFRScoping
Rating.UsingMathcadTMalsohelpstostandardizetheFRPflexuralstrengtheningdesign,and
reduceanyduplicatingeffortsbydesignengineers.
AsampleMathcadTM filewascreatedforBridge00933.Thisbridgewillserveasthebasisfor
thedesignexample.AccordingtotheLRFRScopingRatingsummarysheet,LS00933.XLS,the
exteriorgirderofspan1hasaflexuraldeficientsectionat0.4LwithaRF=0.98(thisisusedas
anexample,andmaynotbeinaccordancewithcurrentrepairpolicy).BecauseitsRF>0.850.80,
anRFPrepairwasconsidered.Thefollowingproceduredemonstrateshowtousethissoftware
to design FRP flexural strengthening in order to increase the girder moment capacity toan
acceptablelevel.
AtthebeginningoftheFRP_Flexure_Design.MCDfile, theauthorhaslisted all theload
modifiers and pertinent load and resistance factors per AASHTO LRFD Bridge Design
Specifications. The load modifiers should be determined based on the existing bridge
configuration and BDDM Section 1.1.7.4. These factors should not be changed, unless the
EngineerofRecorddeemsotherwise.Followingthat,theuserinputstheloadfactors,material
properties,sectionalproperties,deadandliveloadsasusedinthe LRFRScopingRating. All
thosevalues,exceptdeadloads,canbefoundunderPOINTOFINTERESTSUMMARYin
theBRASSoutputfile,EXTGIR.OUT.Pleasenote:
1) SimilartoBRASS,thedepthofgirderisdefinedasthewebdepthonly.Thetotalgirder
depthshouldincludetheflangethickness.
2) Since load ratings only consider the existing wearing surface thickness, and designs
shouldincludeafutureoverlayof25psfperBDDMSection1.1.7.1,theadditionaldeadload
duetowearingsurfaceshouldbeadjustedtotakeintoaccountthefutureoverlay,aswellas
anyfutureutility(ifrequired).
3) TheliveloaddemandsshowninBRASSoutputfilesincludeLLFactorsandDynamic
LoadAllowance. TheLLFactorsshouldberemoved,buttheDynamicLoadAllowance
shouldremain. Thedynamicloadallowance,however,shouldbecheckedforconsistency
betweentheloadratingandthedesignvalues.
4) Incalculatingtheultimatemomentdemand,theusershouldchooseeitherthemaxormin
deadloadfactorbasedonitsimpacttotheliveload.
Currently, ODOT lists only CFRP on the Qualified Products List (QPL). Therefore, this
program was written solely for CFRP applications. Since CFRP products could vary
significantly from one manufacturer to another, it is impossible for the author, nor is the
intentionofthisprogram,tostandardizethesizesandpropertiesofFRP.Therefore,aswithany
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FRPdesign,theDesignermustassumecertainkeymaterialpropertiesoftheFRPproductbefore
carryingoutthedesign.Theassumptionshouldbemadebasedontheapprovedmanufacturers
data.ThefinalFRPdesignbasedontheassumedmaterialpropertiesshouldnotbeconstruedas
asolesourcedesign.
FRPsystemscanbecategorizedintothefollowingfourgroupsbasedonhowtheyaredelivered
tothesiteandinstalled:Wetlayupsystems,Prepregsystems,Precuredsystems,andOtherFRP
forms.Precuredsystemsconsistofawidevarietyofcompositeshapesmanufacturedoffsite.
Typically,anadhesivealongwiththeprimerandputtyisusedtobondtheprecuredshapestothe
concretesurface.Precuredsystemsarerelativelyeasytoconstructandfasttoinstall.Therefore,
forFRPflexuralstrengtheningapplicationsinstalledonlong,flatsurfaceslikegirdersoffits,
Precuredsystemsarerecommended.
Theflexuralstrengthofasectiondependsonitscontrollingfailuremode. Potentialflexural
failure modes include: (1) Crushing of the concrete in compression before yielding of the
reinforcingsteel;(2)YieldingofthesteelintensionfollowedbyruptureoftheFRPlaminate
(FRP Rupture); (3) Yielding of the steel in tension followed by concrete crushing; (4)
Shear/tensiondelaminationoftheconcretecover(coverdelamination);and(5)Debondingofthe
FRP from the concrete substrate (FRP debonding). The program described herein and
illustratedinthedesignexampleistohelptheengineerinvestigatethesefailuremodes.
BasedonFloridaDOTsTemporaryDesignBulletinC0603,itisrecommendednottousemore
thanthree(3)layersofFRPinwetlayupsystems.
Forsimplicity within the program when estimating the ultimate flexural capacity for beams
controlledbyFRPrupture,theprogramassumestheconcretereachesitsmaximumusablestrain
of0.003.Thisapproachdoesnotprovideamoreconservativeresult,buttheerrorintroducedby
this approach is believed to be negligible. It is expressly stated that it is the engineers
responsibility to determine if a refined model is required to more accurately determine the
neutralaxislocationandtheeffectivelevelofconcretestrain.
Incalculatingthedesignflexuralstrengthoftheretrofittedsection,ACI440.2Rrecommends
adjustingthestrengthreductionfactor, ,whenthereinforcingsteelstrainlevelislessthan
0.005. Even though this adjustment is not required in the current AASHTO LRFD
Specifications,itisincludedinthissoftwaretotakeintoaccountthelossofductillityduetothe
application of FRP on reinforced concrete beams. According to ACI 31802, sy can be
assumedas0.002.
Sincethis adjustment is notrequiredbyAASHTO LRFD Specifications,and,normally, the
maximum strain level of a bridge girder reinforcing steel is more than 0.005, the strength
reductionfactor,,isnotadjustedinthisprogram.
As a part of the FRP flexural strengthening design, but not included in this program, the
DesignershalldeterminetheterminationpointofFRPreinforcement.AccordingtoACI440.2R,
FRPstripsshallbeterminatedaminimumofd,theeffectivedepth,beyondthepointonthe
momentdiagramthatrepresentsconcretecracking.Inaddition,thefactoredshearforceatthe
FRP flexural termination location should also be checked against 2/3 of the concrete shear
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strength.Iftheshearforceisgreaterthan2/3oftheconcreteshearstrength,FRPUwrapsare
recommendedtoreinforceagainstcoverdelamination.

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SECTION3

SOFTWAREUSE

Section 3 outlines the process to use the FRP Flexural Strengthening Design Software. A
detaileddescriptionisprovidedinSection2andwithintheDesignExample.
Step1. OpentheFRP_Flexure_Design.MCDfileusingMathcadTMversion11orhigher.
Step2. BasedontheBRASSGirder(LRFD)outputfile,entertheLRFRloadfactors,girder
materialproperties,sectionalproperties,andDeadLoadandLiveLoaddemandsatthe
sectionofinterest.
Step3. SelectthecontrollingPermitLoadCase,andcalculatetheUltimateDemands.
Step4. Calculatethemomentcapacityoftheexistingstructure(withoutanycontributionfrom
theFRPstrengthening).
Step5. Determine the FRP reinforcement dimensions, number of plies, and properties,
accordingtotheFRPManufacturersproductdata.ApprovedFRPproductsandtheir
ManufacturersarelistedintheODOTQPL.
Step6. Determinethecrackedsectionneutralaxisandmomentofinertia,Icr,oftheexisting
structure(withoutanycontributionfromtheFRPstrengthening)usingTrialandError
methodassumingaconcretecompressionstrain,c,of0.003.
Step7. Calculatethesubstratestrain,bi,basedonDL+ADLonly,oftheexistingstructure
(withoutanycontributionfromtheFRPstrengthening).
Step8. Determinethebonddependentcoefficient,m.
Step9. Estimatetheneutralaxislocation,C0,fortherehabilitatedstructure(consideringthe
contributionfromtheFRPstrengthening).
Step10. DeterminetheeffectivelevelofstrainintheFRPstrip,andthecorrespondingstrainin
theexistingtensionreinforcingsteel.
Step11. CalculatethestresslevelintheFRPstripandtheexistingtensionreinforcingsteel.
Step12. CalculatetheinternalforceresultantsandequilibriumbasedontheassumedC0.IfC
differsfromC0bymorethan1%,adjusttheneutralaxislocation(seeStep10above)
untilforceequilibriumissatisfied.
Step13. Calculatetheflexuralcapacityoftherehabilitatedsection.
Step14. CheckservicestressesinthereinforcingsteelandtheFRPstripfortherehabilitated
section.
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Step15. PrinttheFRP_Flexure_Design.mcdfileandsavethefile.
Step16.

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