engineered rebar for concrete structures
TRANSCRIPT
ENGINEERED REBAR
FOR
CONCRETE STRUCTURES
Made in Canada
OUTLINE
i. Why Corrosion is a problem & Typical examplesii. What is an alternative solution (use GFRP Bar)iii. Mechanical & physical properties of MST-BAR™iv. Main advantages of MST-BAR™ over Black Steelv. Approvals & Certificatesvi. Codes, Designs & Standardsvii. Typical Applicationsviii. Cost Analysisix. MST-BAR™ Physical Properties Test Results
• Why Corrosion is a problem?
What justifies the use of MST-BAR™ in today's infrastructures
• Governments & Taxpayers can no longer afford to pay concurrently for replacing, maintenance and expansion of infrastructure
• Corrosion is a dangerous and extremely costly problem and is draining the economy silently
• Safety of infrastructures can become problematic when subjected to harsh environmental conditions
• Steel is an old material, it’s great but often does not fit some applications!
• Typical example of Corrosion on bridges & Seawalls
• Typical example of corrosion on bridge decks
• Typical example of corrosion on Marine Structures
• Typical example of corrosion on Marine Structures
MST-BAR™ -Mega Strength Bar
Mechanical & Physical Properties of Straight GFRP
Stress-Strain Curves
Steel’s maximum stress level is 500MPa and GFRP is above 1000MPa for the same diameter. That is twice the load capacity of steel.
Stress-Strain Chart
Comparison of MST-BAR with Steel and Carbon bar
Actual Test Curve of MST-BAR for 16mm diameter bar
Fatigue Comparison GFRP/CFRP/STEEL
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
100 1,000 10,000 100,000 1,000,000
No. of Cycles (Nos.)
Cra
ck
Wid
th (
mm
)
Comparison of GFRP, CFRP and STEEL Reinforced Slabs
Cycles toFailure @ 60 t
23,162
198,863Cycles
420,684Cycles
Failur
e @ 60 t
23,162Cycles
STEEL
Punching Shear Failure Mode
STEELSTEEL
CFRP
GFRP
Fatigue under 60 t Load Fatigue under 60 t Load Punching Shear Failure Mode
STEEL
GFRP
CFRP
Zero corrosion: 100% resistance to any & all harsh environmental factors, No rusting High chemical resistance: Impervious to salt and other chemical attacks High tensile strength: 2 x stronger than steel with tensile strength of 1000MPa Light weight: 4 x (i.e. 73%) lighter than steel, (2100 Kg/m3 vs.7800 Kg/m3), Ease of transportation Long life span: over 100 years life span (GFRP) vs 25 years (Black Steel) High fatigue life: 20 x higher resistance under cyclic loading (440,000 cycle vs. 40,000 cycle) Non Conductive, & Non-Electromagnetic: Ideal for high electrical field, e.g. power stations Non Magnetic: Ideal for hospitals, MRI rooms, laboratories & other uses Radar Transparent: ideal for Airport Low thermal conductivity: Makes it suitable for use in hot and cold environments, power plants Low thermal expansion: Very low thermal expansion factor results in compatibility with concrete High bonding strength: Much greater bonding strength to concrete (20 Mpa) Ease of cutting & handling: Faster & cheaper installation and site handling Fire rated: Capacity to stand for more than 3 hours in direct fire with minimum concrete cover Sustainable to environment: Environmentally friendly, less Green House Gases while transporting High durability & performance: No maintenance required, No additional project cost, Major savings Min. concrete cover: requires minimum concrete cover i.e. 38mm, (2 ½ x less cracking of concrete) Detection by GPR : Easily detected by GPR No waterproofing: For bridge decks, unique saving for future
Advantages of MST-BAR™ Over Steel Rebar
Dis-advantages of MST-BAR™ Over Steel Rebar
CONCLUSION:
MST-BAR® it is proven for its long-term saving with life of over 100 years vs Black steel of 25 years
MST-BAR® with its proven higher performance not only will not add additional costs to the project; it will certainly result in major savings
Approvals
American Concrete Institution (ACI-440.3)
ASTM D7957
Canadian Standard Association (CSA-S807)
ISO 9001:2008 Quality Control BSI-British Standard Institution
MTO qualified for Grade III(DSM)
FDOT Approved GFRP manufacturing plant
Canadian Design Guide for use of GFRP Bar
Canada -Highway Bridge Design Code Canada – FRP design guide
USA Design Guide for use of GFRP Bar
AASHTO design guide ACI design guide
Standards & CodesInternational
ASTM D7957-17 “Standard Specification for Solid Round Glass Fiber Reinforced Polymer Bars for Concrete
Reinforcement”
Canada
CAN/CSA-S807 (R2015) “Specification for fibre-reinforced polymers” Canadian Standards Association
CAN/CSA-S6-06 (2006) Fibre Reinforced Structures, “Canadian Highway Bridge Design Code” Canadian Standards
Association, pg.693-728
CAN/CSA-S806-02 (R2007) “Design and Construction of Building Components with Fibre-Reinforced Polymers” Canadian
Standards Association
The Structural Innovation & Monitoring Technologies Resource Centre (SIMTReC):
Manual No. 3 (Version 2) ”Reinforcing Concrete Structures with Fibre Reinforced Polymers (FRPs)”, Dr. Sami Rizkalla, Dr.
Aftab Mufti
Manual No. 4 “Strengthening Reinforced Concrete Structures with Externally-Bonded Fibre Reinforced Polymers (FRPs)”,
Dr. Kenneth Neale
Manual No. 5 ”Prestressing Concrete Structures with FRPs” Dr. Ivan Campbell
USA
ACI 440.1R-06 (2006) ”Report on Fiber Reinforced Poly. (FRP) Reinforcement for Concrete Structures”, ACI Committee
440, American Concrete Institute
ACI 440R-07 (2007) ”Report on Fiber-Reinforced Polymer (FRP) Reinforcement for Concrete Structures” ACI Committee
440, American Concrete Institute
ACI 440.5-08 (2008) ”Specification for Construction with Fiber-Reinforced Polymer Reinforcing Bar” ACI Committee 440,
American Concrete Institute
ACI 440.6-08 (2008) “Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials for Concrete
Reinforcement,” ACI Committee 440, American Concrete Institute
AASHTO GFRP-1 (2019) ” AASHTO LRFD Bridge Design Guide Specifications for GFRP-Reinforced Concrete Bridge
Decks and Traffic Railings”, American Association of State Highway and Transportation Officials
Applications
Bridge Decks & infrastructures, Transportation, Highway paving Road side Barriers, Bridge parapets, Paving, Concrete slabs Precast structural elements; e.g. deck panels, culverts, piles, columns, Pipe rings Retaining walls, Box culverts Marine & waterfront Structures, e.g. seawalls, docks, ports, dams, coastal etc. Tunneling; e.g. TBM ring precast segments; Soft eye LRT’s & Heavy Rail (electrical mitigations), rail traverse (plinth) 100% GFRP Bars Structural Strengthening & rehabilitation, bridge Deck replacement Waste water treatment plants Multi-story RC Parkades slabs Nuclear Power Plants & Electrical power plants & Chemical Plants MRI Rooms & Hospitals Airport runway Mining
Typical applications for use of GFRP Bars
Bridge Decks Power Plant Marine & Waterfront Structures
Tunneling (Soft eye)
Hospitals & MRI Rooms
Application of GFRP on RC bridge decks & road paving
Application of GFRP use on RC bridge decks
Application of GFRP use on RC Seawalls & RC Bridge
Application of GFRP use on RC Piles
Application of GFRP use on RC Precast elements
Application of GFRP use on Various RC projects
Application of GFRP use on RC parkade & footings
Use of MST- BAR on bridge rehabilitation in Panama
Other Applications: RC Walls, Floors, Paving
Power Plant
Cost Study: BLACK STEEL
Chloride ions, moisture and salts will penetrate through the membrane and begin corroding its top reinforcement
CONCLUSION: 25 years after the road construction, its asphalt surface will have to be rehabilitated, the membrane would require replacement and the upper reinforcement would corrode needing to be replaced. Considering the life span of MST-BAR® at well over 100 years, the savings that it brings to any and all construction projects is undoubtedly substantial.
Deck with use of Black Steel Rebar
Reducing Your Corrosion Protection by MST-BAR
When using MST-BAR the following protection can be removed by
CSA Code
Membrane
Reducing concrete cover from 70mm to 40mm
Removing C.N.I.
Reducing or Removing Asphalt completely
With Steel With MST-BAR
COST SAVINGS OF MST-BAR™
Transportation Costs, 4 times lower due to its 73% lighter weight
Minimum required concrete cover, 38mm for bars #2 -5 and 50mm for bars #6 -8, (the regular steel bar concrete requires 65mm)
Increase in labor performance and less fatigue for labors during placing the bar result in faster installation
MST-BAR® price with its proven higher performance will not add any extra cost to the project however it will result in saving.
40-60% less expensive than stainless steel rebar while MST-BAR® has much higher performance than the most expensive Stainless-Steel
No water proofing membrane, a unique cost-saving feature
NEVER Epoxy coat paint, re-patch the concrete or replace the rusted bars is no longer needed
MST-BAR, does not required any maintenance
Initial Cost Comparison
Black Steel Galvanized/Epoxy Coated
Stainless-Steel
MST-BAR
Size #5(16mm) #5(16mm) #5(16mm) #5(16mm)
Corrosion Resistance
Extremely weak in corrosive
environment
weak in corrosive environment
Very Good in corrosive
environment
Excellent in corrosive
environment
Strength 450 MPa 450 MPa 500MPa >1000MPa
Weight 7850 kg/m3 7850 kg/m3 8400 kg/m3 2100 kg/m3
Corrosion protection
options requirement
MUST MUST Optional Optional
Price $1.57/m-Not installed
$2.82/m -installed
$2.9/m-Not installed
$3.77/minstalled
$9.5/m Not installed
$12.56/minstalled
$3.1 /m to $4/mNot installed
$4/m installed
Required maintenance every 15-20 years
>75 years >100 years
Typical Initial Cost of Slab with 6.5m length
With Black Steel With MST-BAR
Unit Cost Per Slab
Concrete with
inhibitor250$/m3 406$
Formwork 120$/m2 780$
Topping
60$/m2 Membrane +35$/m2 Asphalt
618
rebar1850
$/Tons260
Sub Total 1804 Note: All the prices are Including installation
Unit CostPer Slab
Concrete with no inhibitor
220$/m3 315$
Formwork 120$/m2 780$
ToppingSingle Membrane:
25$/m2Asphalt Optional
150$
rebar #5 @ 3.1$/m 578$
Sub Total 1823
Required maintenanceafter 10-15 years
Doesn’t Required major maintenancefor over 75 years
• MST-BAR™ - Advantages For Fabricators?
Why use of MST-BAR™ in today's infrastructures
1. MST Bar FRP Manufacturing strong relation with our customer
2. Working hand to hand & in parallel with our customer during estimation to ensure the minimum error
3. Engineering and Testing Report
4. No Minimum quantity!
5. Any size and shape available
6. Ease of handling & installation because of fully ribbed profile
7. Competitive and Flexible pricing
8. Strong QC/QA program
9. Many years of experience in composite industry
BENT MST-BAR™
All sizes of bent MST-BAR may be produced only in the production plant and not at the construction
site, in a specifically dedicated machinery, with an entirely different
process in accordance with the engineering specifications &
drawings.
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