061510 Fiber Reinforced Polymer Composites for Infrastructures Liang

8/3/2019 061510 Fiber Reinforced Polymer Composites for Infrastructures Liang

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NSRP Product Design and Materials Technology Panel MeetingJune 15 16, 2010, Pittsburgh, PA

Fiber Reinforced Polymer

Composites for Infrastructures

CONSTRUCTED FACILITIES CENTERCONSTRUCTED FACILITIES CENTER


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NSF Industry/University Collaborative Research Center

Center for Inte ration of Com osites intoInfrastructure (CICI)

West Vir inia Univ. Lead Universit

Rutgers Univ.North Carolina State Univ.

.

Industry Members 30+

To promote and advance composites for infrastructural

a lications

o Fundamental research

o Applied research

o

o

Education and training


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CICI

Vision:To accelerate the adoption of polymer composites into

-

cooperation

Focus: Innovation and mass-production of advanced

ol mer com osites in a cost effective manner Integration of composite members and subsystems

into infrastructure systems through rapid

Development and growth through industrial supportby targeting at the needs of composites industries aswe as construct on n ustr es


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Composite Application by EndUse/Market Percentage

3.6 billion lbs. of US fiberglass thermoset compositesshipments in 2007

Copyright 2008 American Composites Manufacturers Association


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FRP Infrastructure A lications

Decking for Navy and MarinaDecking for Navy and Marina

Highways & BridgesHighways & Bridges Rapid Housing and Green BuildingsRapid Housing and Green Buildings

t ty o est ty o es

PipesPipes n ur ne a esn ur ne a es

Blast Resistant StructuresBlast Resistant Structures

Rail Road TiesRail Road Ties


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ONR Grant No. N00014-04/05-1-0050/96

Dr. Ignacio Perez, Program Officer

OBJECTIVE

To demonstrate feasibility of an automated pultrusion

process for producing composite sandwich panels (4x 3.5 x unlimited len th which results in a roductwith improved mechanical performance and reducedproduction cost in relation to VARTM process

Target panel: 1/4 FRP face sheets with 3 balsa core


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Vacuum-Assisted Resin Transfer Molding (VARTM)

Seeman's Composite Resin Injection Molding Process (SCRIMP)

Hybrid of VARTM and vacuum bagging


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MILESTONES OF THE PROJECT

20042004 1 sandwich panel (March 3, 2004), 300 sq ft1 sandwich panel (March 3, 2004), 300 sq ft 3.5 sandwich panel (May 18, 2004), 220 sq ft3.5 sandwich panel (May 18, 2004), 220 sq ft

Each 200 sq ft, total 400 sq ft,Each 200 sq ft, total 400 sq ft, No jointNo joint 2004 NSWC2004 NSWC--VARTM panel (Aug 25, 2004)VARTM panel (Aug 25, 2004)

1.25 sandwich panel for bond improvement (Oct 12, 2004, 40 sq ft)1.25 sandwich panel for bond improvement (Oct 12, 2004, 40 sq ft)Note: Better properties thru pultrusionNote: Better properties thru pultrusion

20052005

..

Two 400 sq ft runs (Jan 26 and June 28, 2005, total 800 sq ft)Two 400 sq ft runs (Jan 26 and June 28, 2005, total 800 sq ft) 2005 VARTM panel (May 31, 2005)2005 VARTM panel (May 31, 2005)

Joint evaluation under bending and shear,Joint evaluation under bending and shear, 100% joint efficiency100% joint efficiency20062006

3.5 carbon/vinyl ester sandwich panels3.5 carbon/vinyl ester sandwich panels

Two runs, 300 sq ft (June 23 and Sept 19, 2006))Two runs, 300 sq ft (June 23 and Sept 19, 2006)) FE analysesFE analyses

Orthotropic 3D Model, fully describing the panels static responsesOrthotropic 3D Model, fully describing the panels static responses

Carbon/vinyl ester vs. carbon/epoxyCarbon/vinyl ester vs. carbon/epoxy

3.5 glass/vinyl ester sandwich panels3.5 glass/vinyl ester sandwich panels High Temp Infusion ProcessHigh Temp Infusion Process

80 sq ft (Sept 19, 2007))80 sq ft (Sept 19, 2007)) FE analysesFE analyses

Full scale panel modeling, joint modelingFull scale panel modeling, joint modeling


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PULTRUSION OF GFRP PANEL -2005


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TESTING OF FRP LAMINATES


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SEM MICROGRAPHS OF FIBER/RESIN INTERFACE

Pultruded VARTM

Pultruded


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CFRP Failed Specimens Under Bending

Carbon /VE vs. Carbon/Epoxy

The high performance of carbon fiber has not translated into a proportionate

property improvement of CFRP composites over GFRP, due to the carbon sizing

incom atible with VE. Carbon/e ox should be recommended.


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Finite Element Modeling of FRP

A VARTM Joint

Deflection contours by 3D orthotropic solid model for 40x100 CFRP panel


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CONCLUSIONS Glass/VE

- Pultruded panel is ~15-20% stronger and stiffer, and 50%

- HT infused panel performs as well as VARTM panel, butcosts a third of VARTM panel

- o n e c ency

Carbon/VE- u tru e pane s ~ - st er, - stronger

and 15-20 % lighter than pultruded GFRP panel

- CFRP property improvement over GFRP not

commensurate to cost increase (Carbon ~$15 /lb fiber, $30/lb fabric vs. Glass ~$0.70/lb, $1.5-2.0/lb fabric)

- Carbon/epoxy is strongly recommended, due tocompatibility and durability issues with carbon/VE


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CONCLUSIONS (contd)

Pultrusion process

- Viable and cost effective than VARTM- g qua y pane

High Temp Resin Infusion

- Large size, flat, glass/VE or carbon/epoxy panel

- Viable and even more cost effective than pultrusion

Finite element modeling of panel response- 3D orthotropic solid model (3D geometry + orthotropic

material properties)

- Viable for accurate predictions of deflection, bending stress,and shear stress

- ~100% match between predictions and experimental data


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NSRP Project: Development of

for Low Cost Pultruded Composites

activities at the March 10 11, 2010 Panel Meeting at Biloxi, MS.


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Cost Improvement via Pultrusion or Infusion

DeckDeck

typetype

WeightWeightper unitper unit

CostCostper unitper unit

Cost perCost perunitunit

FailureFailurestressstress

lbs/sq ftlbs/sq ft $/sq ft$/sq ft $/lb$/lb

ksiksi

1# FRP1# FRP 2222 ~80~80 3.643.64 10101. Double trapezoid

2# FRP2# FRP

20002000

1919 ~58~58 3.053.05 3030

~~

20022002

..

4# FRP4# FRP

20032003

1010 ~25~25 2.52.5 3535--4040

2. Revisedtrapezoidal deck

CurrentCurrentFRP *FRP *

1818--2424 6565--100100 3.63.6--55 2525--3030

ConcreteConcrete 9090--120120 ~30~30 0.290.29--0.350.35 44--6 (C)*6 (C)*

3. Lightweightcomposite bridge

< 1 (T)< 1 (T)

4. Low profile bridge deck* Currently used FRP decks.

C: Compression T: Tension


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Highways & Bridges

Market Street Bridge Wheeling, WV


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Highways & Bridges

Goat Farm Bridge, Wirt County, WV


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Highways & Bridges

Pleasant Plain Road Brid e

Montgomery County, Ohio


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Highways & Bridges


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Highways & Bridges

FRP Inspection Walkway

Blennerhassett Brid e

Parkersburg, WV


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Hi hwa s & Brid es

FRP Wraps for rehabilitation


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Highways & Bridges

After

Before

FRP Wraps for rehabilitation


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Highways & Bridges

FRP Rebar, WV Route 9, Martinsburg, WV


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Hi hw Bri

Close-up of instrumented FRPowe ars

FRP dowels, Elkins, WV


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FRP Pavement Panel

Central I-beam (112 ft. long)

View at Section AAA A

I-Beams onright side(12ft. 6 inches)

I-Beams onleft side(12ft. 6

8.7 ft

8.7 ft

inches)

Edge I-beam flangesmay be trimmed toobtain C-shapedchannel

13 ft

8.7ft

13 ft 13 ft

Direction of hollow core cells

Figure 2: Panel layout and connections

New University High School

Morgantown, WV


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Field Implementation of

FRP Pavement Panels

A section of Bakers Ridge Road near University High School,Morgantown, West Virginia was the first to field-evaluate glass

(July 2009, Sponsored by WVDOH)


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Retainin Walls


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FRP Building

CFC-WVU designed, manufactured, and constructed thefirst FRP modular building in 1995 in collaboration with

WV DOT (photos taken on Aug 27, 2009)


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FRP composite home being erected at BRP


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Utility Poles $4 billion treated wood$4 billion treated wood

poles annually in USpoles annually in US

Photo courtesy of Hiel, 2001


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Pipelines

Each year, ~1000 miles newnatural gas pipelines go intoserv ce eac year w e ~

miles is replaced

,gas transmission pipelines arebeing built in the 2001-2010

timeframe at a cost of over $80billion in North America

O Th l E C i (OTEC)


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Ocean Thermal Energy Conversion (OTEC)

OTEC exploits existing ocean temperaturegradients to drive a heat engine

78F

72Fene ts:

Large Renewable Energy Source

3-5 Terawatts available*

Base Load Power 24/7

ColdWaterPip

Closed Cycle OTEC System

Secure source, independent of oil imports Near-carbon free

Fresh Water Production

e

Credit : Lockheed Martin Co

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* A Preliminary Assessment of OTEC Resources ASME 3/2007

OTEC is a renewable energy source for DOD bases and over 80 countries


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Ocean Thermal Energy Conversion Cold Water Pipe

J LJ L

J L Ruhle & Associates


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Pipeline Infrastructure in US

FRP TanksPhoto Courtesy of FRPglasstankandpipe.com


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Composite Turbine Blades for Wind Energy

Global market for wind

2020

Photo courtesy of Wikipedia


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Composite Turbine Blades for Wind Energy

o e ero yn185 blade identifying

axial strains


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Fire Protection of Structures

Fire testing of a FRP composite

panel

Panel withstood 5800 degree F

Acetylene torch for 5 minutes


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himn Fl FRP composites are used in smoke stacks for

Large diameter FRP structures are needed


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Chimneys/Flues

Elbow) (courtesy ofInternational Chimney)

Stack Liner Installation in a

Power Plant (Kelley, 2007)

Engineered Recycled Thermoplastic


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Engineered Recycled Thermoplastic

Composites

Offset Blocks Made of Rec cled Plastic

Recycled Polymer Composite Shell and Used Wood Tie as a Core


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Summary

WVUWVU--CFC has been extensively researching and developingCFC has been extensively researching and developing

FRP com osite materials and s stems for infrastructure andFRP com osite materials and s stems for infrastructure and

military applications for over 20 years.military applications for over 20 years. Many of these systemsMany of these systems

have already been field implemented and are performinghave already been field implemented and are performing

outstandinglyoutstandingly

The CFCThe CFC--WVU team has made major strides in advancing theWVU team has made major strides in advancing the

s a es a e--oo -- ee--ar o compos e sc ences an ec no og esar o compos e sc ences an ec no og es

through integration ofthrough integration of

new fabric architecturesnew fabric architectures

modified resin systemsmodified resin systems innovative processing methodsinnovative processing methods

a wide range of mechanical and chemical (adhesive)a wide range of mechanical and chemical (adhesive)

joining mechanismsjoining mechanisms


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Summary (Contd)

CFCCFC--WVU will continue to work closely with a range ofWVU will continue to work closely with a range of

boundaries of composite applications and expand theboundaries of composite applications and expand thesuccess of fieldsuccess of field--implementing economical and durableimplementing economical and durable

FRP composite structural systems, including naturalFRP composite structural systems, including natural

fiber composites for green buildings.fiber composites for green buildings.

CFCCFC--WVU is currently leading a NSF sponsoredWVU is currently leading a NSF sponsored

Industry/University Collaborative Research Center forIndustry/University Collaborative Research Center for

.. --

industry Consortium will help pave the path toindustry Consortium will help pave the path to

accom lish the above mission.accom lish the above mission.

061510 Fiber Reinforced Polymer Composites for Infrastructures Liang

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