strengthening of concrete structures - seaog.org & tank construction ... rebar discontinuous 5...
TRANSCRIPT
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Strengthening of
Concrete
Structures
Shaun Loeding, P.E.Director
Strengthening Division
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Overall Intent ???
“Design and implement structural solutions
based on our experience and technologies.”
Shaun Loeding, P.E.
Director - Strengthening Division
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Solutions that integrate products, engineering, and construction
Engineering Support Services
State of the Art ProductsSpecialty Contracting
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Total Group
Annual Revenues $400 million
Offerings Products – Engineering – Construction
Employees 2,500 +
Products & Engineering $50 Million
Regional Technology Centers Baltimore, Dallas, & Houston
Construction
Annual Revenues $350 Million
ENR Ranking Largest Concrete Repair Contractor &
27th Largest Specialty Contractor
Projects 2,000-2,500 annually
Typical Range $2,500 to $30 Million
Labor Union & Open Shop Multiple Crafts 2,000-2,500 employees
Markets Served North America & Middle East
Quick Facts
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Quick Facts
International Offices:
Abu Dhabi
Dubai
Qatar
Corporate HQ:
Hanover, MD
North America Offices:
Baltimore
Baton Rouge
Chicago
Dallas
Denver
Detroit
Ft. Lauderdale/Miami
Hartford
Kansas City
Lake Charles
Long Island
Los Angeles
New York
Philadelphia
Pittsburgh
San Francisco
Sarasota/West Florida
Springfield
Offices
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Design-Build Construction Chimney & Stack Construction
Silo & Tank Construction
Pre-Engineered Structures
Repair Services Concrete Repair
Fireproofing
Force Protection
Pipe Rehabilitation
Strengthening
Corrosion & Cathodic Protection
Refractory Linings
Equipment & Pump Foundations
Moisture Control & Waterproofing
Building Envelope
Historic Restoration
Maintenance Services
Industry Leading Specialty
Contracting Services for New & Existing Structures
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Repair Services Concrete Repair
Fireproofing
Force Protection
Pipe Rehabilitation
Strengthening
Corrosion & Cathodic Protection
Refractory Linings
Equipment & Pump Foundations
Moisture Control & Waterproofing
Building Envelope
Historic Restoration
Maintenance Services
Industry Leading Specialty
Contracting Services
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State of the Art Products
Engineered Solutions
Products & Systems Strengthening
Force Protection
Pipe Repair & Upgrade
Corrosion Control
Moisture Control
Concrete Restoration
Equipment Foundations
Post Tensioning
Engineering Support Investigative
Condition Assessment
Engineering Product Customization
Design – Assist
Specialty Full Design
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Agenda
Introduction
FRP (fiber reinforced polymers)
- Most common uses for FRP
- Design strategy (ACI 440.2R-08)
- Installation techniques and QA/QC
- FRP limitations & fire protection
- Case Studies
Conventional Techniques
- Section Enlargement
- External Post Tensioning
New Strengthening Technologies
(DUCON – micro-reinforced concrete)
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Why Strengthen??
Construction Defects
Design Deficiencies
New Loads
Deterioration
Seismic Upgrades
Blast Upgrades
Strengthening =
Upgrading Structural Capacity
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Design-Development Conceptual designs and associated
budgets
Specification support
Aid in overall engineering and strengthening analysis
Site visits
Solution/repair strategy
Construction Final design calculations and shop drawings
(PE stamped/sealed upon request)
QA/QC and Safety Program – project specific
Trained, certified and experienced installers
Direct Services
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FRP Composite – what is it ???
FRP = Fiber-Reinforced Polymer
Composite = two or more materials that when combined
create one composite behaving system
(fiber + epoxy = composite, with new and distinct properties)
OTHER NAMES USED: Carbon fiber
Carbon FRP (CFRP) or Glass FRP (GFRP)
Fiber reinforced composite (FRC)
Fiber wrap
Externally bonded FRP reinforcement
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“Strengthening” Typically Carbon FRP (CFRP)
Upgrade flexure and/or shear capacity of member
CFRP = higher strength, higher material cost
FRP Applications
“Restoration” Typically Glass FRP (GFRP)
Corrosion protection, spall protection
GFRP = lower strength, lower material cost
NOTE: CFRP and GFRP = lightweight, low profile, corrosive resistant, durable
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FRP Applications
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CFRP strip – 1 layer, 12” wide = (1)-#5 rebar (60ksi) Typical application uses CFRP strips of 8”, 12” or 24” width
Typical application uses 1 to 4 layers of CFRP
CFRP may provide up to 40% additional capacity to an element Typical application requires 20%-25% additional capacity
CFRP does not stiffen an element i.e. does not aid in reducing deflections or aid in satisfying service conditions of
an element
“Rules of Thumb” –
flexural strengthening with CFRP
12”
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440.2R-08
FRP Design Principles & Engineering Considerations
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FRP Flexural Design Concepts
2
cdfAM 1
ssn
h d
b
c
ec
es fs
gf 'c
1c
2
1chfA ff
f
ffef
Strain in FRP?
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LC
FRP – Design Strain Limits
“Peeling” de-bonding
effect at ends
“Un-zipping” de-bonding
effect at flexural cracks
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20
40
60
80
100
120
140
160
180
200
0 0.002 0.004 0.006 0.008 0.010 0.012 0.014 0.016
Strain
Str
ess (
ksi)
Steel
GFRP
0
CFRP
Modulus, E:
Steel – 29,000ksi
CFRP – 12,000ksi
GFRP – 3,000ksi
Design – Stress/Strain Relationship
Ultimate (Rupture)
Flexural Design
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DEFLECTION
LO
AD
Member
with FRP
Original RC
Member
“Supplemental Reinforcement”
FRP Strengthening Limits – ACI 440.2R
New 440.2R Loads:
1.1DL+0.75LL
New Ultimate Loads:
1.2DL+1.6LL
Existing strength without FRP should be able to support demand from load case
of 1.1DL+0.75LL (ACI 440.2R, Eq. 9-1)
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DEFLECTION
LO
AD
Member
with FRP
Original RC
Member
“Supplemental Reinforcement”
FRP Strengthening Limits – Fire Event
New Service Loads:
1.0DL+1.0LL
(due to change)
New Ultimate Loads:
1.2DL+1.6LL
2Hr Fire
Reduced
Capacity
Existing strength without FRP should be able to support typical service loads
(1.0DL+1.0LL) after 2Hr Fire
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Intumescent
(Burning-
ASTM E84)
Fire Protection Strategies
Protect FRP for Applicable Burn
Characteristics per ASTM E84
Intumescent Topcoat
(Flame spread & smoke density)
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FRP Installation – General Procedures
Prepare substrate surface
Provide surface primer/thickened epoxy on prepared
substrate
Saturate fabric sheet
Install saturated fabric sheet
Provide coating
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Substrate Preparation for Bond
Open pores!
1 2 3
1.Abrasive
blast2.Dustless
grinding
& vacuum
3.Water blast
& dry
Primer
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Surface Preparation
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Primer/Thickened Epoxy to Substrate
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FRP Sheet Saturation
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FRP Sheet Saturation
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FRP Sheet Installation
Prepared substrate Saturated fabric
sheet
Primed
substrate
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QC Acceptance Criteria
Bond
Pull of tests to determine bond strength to
concrete
Minimum 200 psi
Delamination
Limits of delaminated FRP area to ensure adequate
performance
Material Testing
Tensile tests of laminate from field
Tap Test
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FRP Pull off Bond Test Requires Min. 200psi
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Condo Building - multiple strengthening techniques
due to design defects
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Slab Strengthening – FRP layout
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Slab Upgrade – FRP strips
(positive bending)
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Slab Strengthening
(negative bending)
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Slab
Strengthening
Wall removal required
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Condo Building - multiple strengthening
techniques due to design defects
Shear collars Column enlargement
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New Penetrations in Existing Slabs
One direction
Two direction
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New Slab Penetrations
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Existing Concrete Joists
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Precast Double Tees - Stem cracks
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Install FRP Shear “U” Wraps
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Guggenheim Museum
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Guggenheim Museum
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Guggenheim
Museum
Chip
Open
crack
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Guggenheim Museum
Steel
T-Section
Rebar
Discontinuous
5”
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Guggenheim
Museum
T-Bars
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Guggenheim Museum Prior to insulation
and dry wall
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Grout
Guggenheim Museum Thru wall detail
BondBond
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Guggenheim
Museum
Web Wall
Bracket
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Lack of plastic hinge confinement
MOMENT RESISTING FRAMES - Column failure
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(Performance of an RC Corner Beam-Column Joint by Engindeniz et al., 2007)
Beam/Column shear strengthening
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FRP Wrap – Increase Axial Load Capacity
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Column Repairs - Low Strength Concrete
Enlarge FRP
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Power Plant - Missing Seismic Steel
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Power Plant - Missing Seismic Steel
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Power Plant - Missing Seismic Steel
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Power Plant - Missing Seismic Steel
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FRP “Near-Surface Mounted” (NSM) Rod -
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FRP “Near-Surface Mounted” (NSM) Rod -
CFRP Bar Installation Finished Product
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NSM Rod- Bridge Decks ( I-75, Florida)
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NSM Rod- CMU Wall Application
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I-75 Rouge Bridge, MIColumn FRP Upgrade
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Shear Upgrade with FRP
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Completed Bridge Pier FRP Strengthening
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FRP rod
Epoxy paste
FRP reinforcement
FRP Sheet
FRP Strengthening –
NSM Anchorage of Shear Reinforcing
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Far Rockaway, Queens, NY – Elevated ‘A-Line’
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Far Rockaway, Queens, NY – Elevated ‘A-Line’
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Far Rockaway, Queens, NY – Elevated ‘A-Line’
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Far Rockaway, Queens, NY – Elevated ‘A-Line’
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Enlargement- “Composite Behavior”
NewExisting
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Enlargement: Self-Consolidating Concrete
26-28”
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Section Enlargement
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F
F
NEW LOAD
Uplift
at Deviator
Dead end
Live end
External Post Tensioning Upgrade
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External Post Tensioning
Encased in Concrete
PT Beam
Damaged
From Snow
Load
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External Post Tensioning
Encased in Concrete
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External Post Tensioning
Encased in Concrete
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DUCON® Slurry-infiltrated Micro-Reinforced
Ultra High Performance Concrete
MicroMat®
Micro-Reinforcement
Tensile: 60 - 80 ksi
DUCON®
Self Consolidating Slurry
Compressive: ~ 20 ksi
DUCON®
Ductile Concrete
Compressive: ~ 22 ksi
Tensile: ~ 3 ksi
Shear: ~ 2 ksi
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Bundled Wire Layers
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Multiple layer mat
Wire Size: 0.04” to 0.06”
Wire Spacing: 0.3” to 1.0”
Wire Strength: 60ksi or 80ksi
(Plan View)
mesheswire
Micro-reinforcement mesh
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Concrete Slurry Infiltration
15,000psi+
slurry
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2 i
nc
he
s
Diameter
0.9 inch
10-12 MicroMat layers
per inch
Micro-reinforced Concrete Slurry
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Bending Performance
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Original Concept - Thin Load Bearing Elements
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12"
4"
BS5-D
36"
12"
15 1/2"
17 1/2"
U-Shape Ducon
(Thickness 1.75")
16"
1
1
4"
U-Shape Ducon
(thickness varies)
11'-0"
10'-6"
10'-0"
Beam BS2-D & BS5-D
12"
4"
Beam BS2-D
U-Shape Ducon
(Thickness 1")
36"
12"
14"
16 3/4"
T-Beam Details
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Surface Preparation
- Roughen surface to ¼” amplitude (CSP-7)
- No dowels required
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Install Steel Mesh (specified layers)
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Slurry Pumped into Forms
(Material Flow – Plexiglass Window)
Slurry Pumping
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Cured and Finished Product
Test Beam
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DUCON - Slab Overlay
(structural and/or finish upgrades)
• Crack sealing
• Crack control
• Water-tight
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Precast Elements
Thin and strong
Column forms, walls
Strengthening – enlargement
Beams and slabs (flexure, shear)
Columns (axial, seismic)
Surface Repair
Crack sealing, crack control, water-tight
Industrial flooring
Blast Protection
Energy dissipation
Fragmentation and spall protection – “safety net”
Primary Applications - Review
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Spall and Breach
RFC
36 inch
RFCBREACH
& SPALL
18 inch
SPALL
18 inch
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0’
10’
20’Slab, Column Or Wall
Primary Damage
mode: Flexure
Effects:
Rotation
Cracking
Minimal Spalling
0ft 3ft 8ft 20ft
STAND
OFF
CHARGE
Stand Off & Perimeter Blast Threats
(>20’ standoff distance)
Typical Blast Pressure Range:
4 psi - 10 psi
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0’
7.5’
15’Slab, Column Or Wall
0’ 3 20ft
MID
RANGE
CHARGE
Mid Range Blast Threat
8
Primary Damage
mode: Flexure
Secondary Damage
mode: Shear
Effects:
Some Spalling
Small Projectiles
No Breach
(>8’ and < 20’)
Typical
Blast Pressure:
10 psi - 20 psi
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0’
6’
12’Slab, Column Or Wall
CLOSE
RANGE
CHARGE
0’ 3 20ft
Primary Damage mode:
Shear
Secondary Damage
Mode: Flexure
Significant Spalling
Large Projectiles
Possible Breach
Close Range Threat
8
(>3’ and < 8’)
Typical
Blast Pressure:
20 – 200 psi
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0’
4’
8’
Primary damage mode:
Shear
Effects:
Breach (certain)
Shock wave penetrates
Heavy Spalling
Large projectiles
0’
Contact Detonation Blast Threat
Slab, Column Or Wall
3’
CONTACT
CHARGE
Typical
Blast Pressure:
200 psi – 100K psi
(< 3’)
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Shear Strength Test
DUCON® Ultra High Performance Concrete
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RFC
Rear Side
100 lb Close Range Detonation Testing
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Protected Side
No SpallNo Breach
Attacked Side
Contact Detonation Test Results
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Cast in Place
Walls
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DUCON® INSITU SPALL LINERS (WALLS)
3”
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Cast in Place
Walls
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Cast in Place
Walls
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THE PARKLAWN BUILDINGDepartment of Health and Human Services
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PHASE 1
PHASE 2
PHASE 3
The Parklawn Building
1200 Columns, 21 Column Sizes, 8 Different Conditions
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Column Blast Shields
Install wire mesh
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Column Blast Shields
Form and pump cement
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Column Blast Shields
Partial height column jacket Full height column jacket
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DUCON - Precast Wall Panels
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Blast Mitigation for Columns for Truck Sized Bomb at Curbside
No FRP
14”
14”
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Blast Mitigation for Columns with FRP
No FRP
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Blast Mitigation for Columns with FRP
With FRP
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Overall Intent ???
“Design and implement structural solutions
based on our experience and technologies.”
Shaun Loeding, P.E.
Director - Strengthening Division
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Concluding remarks – THANK YOU !
• Please visit www.structural.net and www.structuraltechnologies.com
• Technical design support
• Budgetary estimate support
• Repair and QA/QC specs
• Contracting services
• Technical “Lunch-Box” training seminars available:
- Strengthening - Corrosion Protection - Concrete Repair
- Building Envelope - Waterproofing - Force protection
• Current projects?
• Local contact: Shaun Loeding, P.E.
631-488-7421