HISTORY - FRP Fiber Reinforced Materials

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

DOT-Federal Highway Administration

HISTORY - FRP POST WW-II APPLICATIONS

Boat Hulls Radomes Minesweeping Vessels Bath Tubs Covers
HS, CR, LW - New Developments in Filament Winding and Pultrusion
DOT-Federal Highway Administration

HISTORY - FRP
POST WW-II APPLICATIONS-2

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

DOT-Federal Highway Administration

HISTORY - FRP
POST WW-II DOMESTIC APPLICATIONS

Bath Tubs Covers Railings Housing Components Architectural Components Ladders Electrical Equipment

DOT-Federal Highway Administration

HISTORY - FRP
POST WW-II RECREATIONAL USES

Fishing Rods Tennis Rackets Ski Equipment Golf Clubs Recreation Boats Skates

DOT-Federal Highway Administration

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

TOTAL
Source: SPI CI, April 99

3223.5 3421.7 3494.0

DOT-Federal Highway Administration

FRP - CIVIL STRUCTURES

CURRENT FIELD ACTIVITIES

Pedestrian Bridges Highway Bridges Seismic Retrofit Columns Bridge Strengthening Bridge Repairs

DOT-Federal Highway Administration

FRP TECHNOLOGY
CHARACTERISTICS
High Strength High Resistance to Corrosion and Chemical High Resistance to Elevated Temperature High Resistance to Abrasion Toughness Fatigue Light Weight

DOT-Federal Highway Administration

FRP TECHNOLOGY
ADVANTAGES
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

DOT-Federal Highway Administration

FRP TECHNOLOGY
DISADVANTAGES -1
High First Cost Creep and Shrinkage Potential for Environmental Degradation (Alkalis Attack, UV Radiation Exposure, Moisture Absorption, etc.) Consistency of Material Properties

DOT-Federal Highway Administration

FRP TECHNOLOGY
DISADVANTAGES - 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)

DOT-Federal Highway Administration

FRP TECHNOLOGY PUBLIC CONCERNS

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

DOT-Federal Highway Administration

MANUFACTURING PROCESS
COMMON TO CIVIL APPLICATIONS

Pultrusion Filament Winding Layup

DOT-Federal Highway Administration

WHAT IS FRP COMPOSITES COMPONENTS

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

DOT-Federal Highway Administration

FRP TECHNOLOGY
MECHANICAL PROPERTIES
Fiber Types Fiber Orientations Fiber Architecture Fiber Volume (30-70%)

DOT-Federal Highway Administration

FRP TECHNOLOGY FIBER TYPES

Glass Aramid Carbon (Graphite) Boron Polyvinyl alcohol (PVA)

(Available in Japan)

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP TECHNOLOGY
FIBER ARCHITECTURE
Braiding (2D & 3D) Knitting Weaving Stitched Chopped

DOT-Federal Highway Administration

FRP TECHNOLOGY CARBON FIBER

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

DOT-Federal Highway Administration

FRP TECHNOLOGY ARAMID FIBER

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

DOT-Federal Highway Administration

FRP -TYPICAL PROPERTIES

FIBER
E-Glass S-Glass CF-Pan C-Pitch GP Pitch UHM Aramid Ceramic Nylon
STRENGTH (KSI) MODULUS (MSI) STRAIN (%)

350 500 600 200 400 500 100 50

6 6 33-50 6 70-120 10-20 10-40 0.5

2 3 2 0.3 0.5 2 2 5-50

DOT-Federal Highway Administration

Source: Tonen Energy Corp

TECHNOLOGY FIBER PROPERTIES

Carbon (600 ksi)
fiber stress (Gpa) 4 3 2 Aramid (500 ksi)

E-glass (350 ksi)

1
1 2 3 4 fiber strain (%) DOT-Federal Highway Administration

FRP TECHNOLOGY RESIN SYSTEM

Thermoplastics (melts when heated,

solidifies when cooled, no permanent curing)

Thermosets (cures permanently by

irreversible cross linking at elevated temp.)

DOT-Federal Highway Administration

FRP TECHNOLOGY
RESIN FORMULATIONS
Viscosity Reactivity Resiliency High Deflection Temperature (HDT)

DOT-Federal Highway Administration

FRP TECHNOLOGY RESIN TYPES

Unsaturated Polyesters Epoxies Vinyl Esters Polyurethanes Phenolics

DOT-Federal Highway Administration

FRP - RESIN SYSTEM

UNSATURATED POLYESTERS - 1

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

DOT-Federal Highway Administration

FRP - RESIN SYSTEM

UNSATURATED POLYESTERS - 2

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

DOT-Federal Highway Administration

FRP - RESIN SYSTEM EPOXIES

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

DOT-Federal Highway Administration

FRP - RESIN SYSTEM VINYL ESTERS

Good Workability Fast Curing High Performance Toughness Excellent Corrosion Resistance

DOT-Federal Highway Administration

FRP - RESIN SYSTEM POLYURETHANES

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

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP TECHNOLOGY FILLERS

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

DOT-Federal Highway Administration

FRP TECHNOLOGY FILLER TYPES

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

DOT-Federal Highway Administration

FRP TECHNOLOGY ADDITIVES

Improved Material Properties Aesthetics Enhanced Workability Improved Performance

DOT-Federal Highway Administration

FRP TECHNOLOGY ADDITIVE TYPES

Catalysts Promoters Inhibitors Coloring Dyes Releasing Agents Antistatic Agents Foaming Agents

DOT-Federal Highway Administration

FRP TECHNOLOGY
SMART MATERIALS
Innovative Design and Application Customized Product for High Performance Versatility Complex Design Process Materials, Processing, Configurations

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP - DESIGN
AVOID ABRUPT THICKNESS

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

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP - DESIGN
GEOMETRICAL 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

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP - DESIGN
HYBRID 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

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP - DESIGN
BONDED JOINTS

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

DOT-Federal Highway Administration

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

DOT-Federal Highway Administration

FRP - DESIGN
CONNECTION DETAILS
Local Stress Flow Overall Load Path Weak Links Manufacturing Defects Fabrication Irregularities Select Proper Fasteners

DOT-Federal Highway Administration

FRP TECHNOLOGY FUTURE 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

DOT-Federal Highway Administration

FRP TECHNOLOGY CONCLUSION - 1

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

DOT-Federal Highway Administration

FRP TECHOLOGY CONCLUSION - 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

DOT-Federal Highway Administration