Structural Strengthening of Concrete with FRP Composites

David White, P.E.

Miklos Basler

Sika Corporation
201 Polito Avenue
Lyndhurst, NJ 07071

Presented at a meeting of the Thermoset Resin Formulators Association at the Hilton Suites Chicago
Magnificent Mile in Chicago, IL, September 15-16, 2008.

This paper is presented by invitation of TRFA. It is publicly distributed upon request by the TRFA to assist in the
communication of information and viewpoints relevant to the thermoset industry. The paper and its contents have
not been reviewed or evaluated by the TRFA and should not be construed as having been adopted or endorsed
by the TRFA.

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Synopsis
It is becoming preferable, both environmentally and economically to upgrade bridges rather than to
demolish and rebuild them. The deterioration of bridges from environmental influences and from traffic
loads require rehabilitation and renewal programs to maintain even current service levels on the bridge
infrastructure network. There are increased demands for high durability, longer service life, reduced
maintenance cost and cost/performance optimization. Advanced Composite Systems have now
become a viable method of strengthening existing bridges worldwide. This paper presents the
evolution of carbon fiber systems since 1991, including relevant Test Reports for Bridge Engineering as
well as their worldwide application.

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Miklos Basler, now retired, was the Key Account & Business Development Manager for Structural
Strengthening for Sika Services AG, Zürich, Switzerland. Miklos is a member of ACI and the Swiss
Society of Engineers and Architects, fib Task Group 9.3 - FRP reinforcement for concrete structures
and of the IABSE Working Commission 8: Maintenance and Repair of Structures. He holds a B.S.C.E.
from the Faculty of Civil Engineering, University in Belgrade.

David White, P.E. is the Director of Technical Services for Sika Corporation, Lyndhurst, NJ, USA. He
is a voting member of ACI Committee 440, as well as Committees 503 and 548. David is also active in
the International Concrete Repair Institute Strengthening Committee and the American Segmental
Bridge Institute. He holds a B.S.C.E. from Columbia University in New York and an M.S.C.E. from
Polytechnic University in Brooklyn, N.Y.

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1. Introduction
In today’s world, construction engineers are faced more and more frequently with the task of
strengthening existing Bridges in order to secure or even increase their load bearing capacity. Many
different strengthening techniques are available, such as installing additional steel, external post-
tensioning, bonded reinforcement, increasing the concrete cross-section, etc. The use of bonded steel
plates has been used successfully since the late 1960’s. External plate bonding is a method of
strengthening which involves adhering additional reinforcement to the external faces of a structural
member.
As a result of extensive research and development projects at the Swiss Federal Laboratories for
Materials Testing and Research (EMPA), Dübendorf, Switzerland it was proven that the use of steel
plates can be replaced with composite materials. The high-strength Carbon Fiber Reinforced Polymer
(CFRP) plate system was applied for the first time outside the laboratory in 1991 for strengthening the
Ibach Bridge in Lucerne, Switzerland.
In virtually all applications for bridge strengthening, advanced composite systems have been proven to
be structurally efficient, easy to handle and install on job site, and cost competitive when compared to
other conventional strengthening methods.

Why do bridges need strengthening?

There are many reasons why it may be necessary to strengthen bridges. These include:

– Corrosion of reinforcement – Corrosion of pre-stressing cables

– Modified Codes and Standards – Increased permanent and traffic loads
– Inadequate structural design – Seismic retrofitting

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What do we achieve by adopting this Technique?

In adopting the technique of advanced composites systems it is possible to:

– Increase the flexural strength – Increase the shear strength
– Increase the seismic resistance – Increase the confining strength

Advanced composite systems are comprised of fibers (typically carbon, glass, or aramid) and resins
(typically epoxy resins). Only long term tested (fatigue resistant) and approved systems should be
recommended for strengthening purposes in Bridge Engineering.

2. CRFP Plate Systems

2.1 System components

2.1.1 CFRP plates

The CFRP plates consist of individual carbon fibers, each having a diameter of approximately one five
thousandth of a millimetre. The fibres are aligned longitudinally and manufactured using the pultrusion
process. CFRP plates exhibit linear elastic behaviour up to the point of failure. Using different carbon
fibers allows plates to be manufactured with different material properties.
Table 1 Material properties of CFRP plates
E-modulus Tensile strength Elongation at break
N/mm2 N/mm2 %
Standard (S) Modulus 165,000 2,800 > 1.7
Medium (M) Modulus 210,000 2,400 > 1.2
High (H) Modulus 300,000 1,300 > 0.45

The chemical resistance of CFRP

plates against pollutants is very
good. The carbon fibers and the
epoxy matrix have long-term
resistance against concrete pore
water, de-icing salts and hydrous
acid solutions. CFRP plates are
available in different widths
between 50mm to 150mm and
thickness of 1.2mm to 1.4mm.
CFRP plate systems are
particularly suitable for flexural
strengthening, in-situ rehabilitation
as well as for pre-stressing.

Fig. 1 - Typical Stress-strain

diagram

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2.1.2 Epoxy adhesive
Two component epoxy resin systems are well suited for the bonding of CFRP plates to concrete, steel,
wood or masonry. This type of adhesive has very high mechanical strengths as well as good chemical
resistance against aggressive media. Good wetting properties on concrete, wood, etc., ensure good
bond characteristics.
The main function of the adhesive layer is to transfer the forces between the composite material and
the substrate, such that they will act monolithically.

The following properties are important for high strength structural bonding:
– High bonding strength - High cohesive strength
– Low creep - Good resistance against humidity and
alkalinity

3. Relevant Test Reports

Before strengthening of bridges or structures exposed to dynamic load with advanced composite
systems, two basic questions need to be answered. They are:
1) What is the influence on the load-bearing capacity of structure exposed to dynamic and
vibrating loads during cure of the structural adhesive?
2) What is the influence on the load-bearing capacity of structure exposed to fatigue loading
during the life span of the structure?
To answer these questions Sika commissioned the Swiss Federal Laboratories for Material Testing and
Research (EMPA), Dübendorf with the objective of investigating the above-mentioned influences.

3.1 Bonding of CFRP plates under oscillating load

Tests were performed in two phases on pre-stressed concrete slabs with a span of 3.8m and a
thickness of 18cm. In the first phase, CFRP plates were applied under dynamic loads. In the second
phase, these strengthened specimens were subjected to static loading until failure. See EMPA test
reports [1].

Fig. 2 - EMPA Test set-up Fig. 3 - CFRP plates debonding

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 Table 2 Test results
Test Specimen Fbr Ybr εbr
[kN] [mm] 0
/00
Specimen 1
Curing without oscillation 161 70 6.61
Specimen 4
Curing with oscillation 176 75 6.55

Fbr : Ultimate / Failure load εbr : Strain in CFRP at delamination

Ybr : Mid-span deflection
There was little difference in the load-bearing capacity, mid-span deflection and strain in the CarboDur
at debonding of test specimens with or without oscillating loading during curing of Sikadur adhesive.
Therefore, bridges can remain open to traffic during application of CFRP plate system.

3.2 Fatigue and failure test

Tests were performed on a standard EMPA T-beam with a span of 6.0m subjected to a four point
bending test. All test beams, BO, T2, B1 and B2 had identical steel reinforcement and the beams T2,
B1 and B2 received an identical CFRP strengthening. The fatigue test subjected beams B1 and B2 to
5 million loading cycles prior to proceeding to ultimate loading. See EMPA test report [2] and Ph.D.
thesis [3].

Fig. 5 - B1-Beam before

Fatigue test

Fig. 4 - EMPA Test set-up Fig. 6 - B1-Debonded

CFRP plate

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 Table 3 Static failure test results
Test Specimen Ybr εbr Fbr Comparison Fbr
[mm] ‰ [kN] %
BO, reference beam 84 - 636 78
No fatigue test
T2, with no fatigue test 83 9.15 815 100
B1/B2, with fatigue test 78 8.50 743 91

Ybr : Mid-span deflection of beam

εbr : Strain in CFRP plate at delamination
Fbr : Ultimate load
The comparison of the static failure test results showed a maximum 9% difference in the load-bearing
capacity between identical specimens T2 and B1/B2 with and without a fatigue test, and between
ultimate strain in CFRP plates at delamination.

4. Case Studies

4.1 Bridges in the Republic of Macedonia

In 1999, the 1st TMCA (Transport Movement Control Agency) of the US Army in Germany
initiated the need for transportation of military equipment by means of HETS (Heavy Equipment
Transport System) military vehicles having nine axles and a total weight under loaded conditions
of 104.3 tons. The objective was to achieve conditions for safe crossing of loaded HETS military
vehicles over the bridges on the National road M-2 between Kumanovo and the Bulgarian
border.
On behalf of the US Army a Report on Structural Analysis of Bridges on M-2 was prepared by
the Working Group TMCA / Bridges from the Faculty of Civil Engineering in Skopje. A total 20
bridges had insufficient loading capacity for the HETS and the US Army accepted the proposal
of the Consultant to proceed with strengthening of these Bridges using CFRP plates as well as
CFRP composite fabric systems.
The U.S. Army Corps of Engineers, Rock Island District under the leadership of Mr Mark R.
Hoague, P.E. and Mr Mohamed M. Moussa, PhD, P.E, carried out the Design review.

Table 4 Basic Information

Project stage Total Bridges CFRP Plates CFRP Fabrics
[m] [sqm]

Phase 1 20 15,000 1,300

Phase 2 10 10,000 700

TOTAL 30 25,000 2,000

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 Fig. 7 - B7 Application on site Fig. 8 - B7 Applied Systems

The objective was to verify the model used by the Consultant for the bridge analysis, to check and
verify the results of the analysis and design due to loaded HETS vehicle and to confirm the efficiency
of the CFRP plates for bridge strengthening. In addition, load testing was performed to confirm the
performance of the system. Test were made on bridges before and after strengthening with the
Composites, measuring stresses in re-bars, concrete, CFRP plates as well as vertical deflection of
bridges.

Fig. 9 - Bridge B37 – Testing instruments

Main girder - Strains

ORI: Before strengthening

STR: After strengthening

Fig. 10 - Bridge B37 – State of Strain

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 Conclusions from the Test Program
The measured strains (stresses) and displacements in the strengthening conditions were
typically smaller than corresponding ones for the unstrengthened condition. The measured
strains in the strengthened condition follow Hooke’s Law and Bernoulli’s principle.
The test results proved that the proper behaviour of the bridges is in accordance with the
applied Design Approach and that the increased load bearing capacity under service conditions
up to the level of anticipated influences due to HETS, is appropriate without any restriction of
limitation in regular traffic flow.

4.2 The Narrows Bridge, Perth Western Australia

Built in 1960’s the Narrows Bridge connects the Perth central business district with the southern
Suburbs of the city. Due to the increased traffic loads, the main girders of this prestressed
concrete continuous I-beam bridge did not have sufficient load-bearing capacity.
Length: 55.0 + 70.0 + 110.0 + 70.0 + 55.0 = 360.0 m
Width: = 16.0 m

Fig. 11 - View Fig. 12 - Cross section / Details

Solution
Strengthening of each main
girder with 6 CFRP plates, with
a maximum length of 55.0 m.
The applied CFRP plates were
protected from UV light with a
pigmented, water-based, acrylic
coating.

Fig. 13 - Application of CFRP Plates

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4.3 The Katerini Bridge, Greece
One of the first prestressed concrete bridges in Greece, the Katerini Bridge was built in 1960
and is situated on the National Road Thessaloniki-Katerini. Due to increased permanent and
traffic loads the prestressed main girders had insufficient flexural load-bearing capacity.
Length: 35.0 + 35.0 + 35.0 = 105 m
Width: = 12 m
Bonding CFRP plates to the soffits increased the flexural strength of the 28m main girders.
Using a special heating device, the epoxy resin was accelerated to cure in four hours.

Fig. 14- - View Fig. 15 - Cross Section

Fig. 16 - Application of epoxy resin Fig. 17 - Applied CFRP plates

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5. Conclusions
As a result of intensive theoretical investigations, research, and laboratory testing, the strengthening of
Bridges with advanced composites has now become a state-of-the-art technique in the construction
industry. Carbon fiber systems are now being used more and more for bridge strengthening. Their
excellent long-term resistance, high corrosion resistance and ease of installation offer unparalleled
advantages to the bridge engineering marketplace.

6. Acknowledgement
The authors acknowledge the support of:
• Mr Kenneth C. Crawford, Chief Engineer, Support Operation Engineering (SOE), 21st Theater
Support Command (TSC) of US Army – Europe
• Prof. Dr. Tihomir Nikolovski, Project Manager, Working Group TMCA / Bridges, Faculty of Civil
Engineering, Skopje, Republic of Macedonia
• Mr Christoph Czaderski, EMPA, Dübendorf, Switzerland
in preparation of this paper for providing information on project i.e. test results, project documentations,
photos etc.
Special thanks are expressed to Mr Mark R. Hoague, P.E. and Mr Mohamed M. Moussa, PhD, P.E.
from USACE, Rock Island District, Illinois for their efficient co-operation during the whole project
development.

7. References
[1] EMPA Test Reports 170’569e-1, 418931E and 418931E/1. Sika CarboDur Structural
Strengthening Systems. Bonding of CFRP plates under dynamic load. Static testing of pre-
stressed narrow slabs post-strengthened with CFRP strips. Dübendorf, 1998 and 2001.
[2] EMPA Test Report 402’017E/2: Sika CarboDur Structural Strengthening Systems. Fatigue and
Failure Test. Test beams B1 and B2, Dübendorf 1999.
[3] DEURING M., “Verstärken von Stahlbeton mit gespannten Faserverbundwerkstoffen”, Diss. ETH
Nr. 10199, Zürich, 1993

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