HISTORY - FRP Fiber Reinforced Materials Straw in Clay (Brick, Roof, Walls) Glass Fibers in Concrete Glass Fibers in Polymer

HISTORY - FRP POST WW-II APPLICATIONS Boat Hulls Radomes Minesweeping Vessels Bath Tubs Covers HS, CR, LW - New Developments in Filament Winding and Pultrusion

HISTORY - FRP POST WW-II APPLICATIONS-2 Pressure Vessels Submarine Parts Rocket Shells Aircraft Components Automobile Bodies & Parts

HISTORY - FRP POST WW-II DOMESTIC APPLICATIONS Bath Tubs Covers Railings Housing Components Architectural Components Ladders Electrical Equipment

HISTORY - FRP POST WW-II RECREATIONAL USES Fishing Rods Tennis Rackets Ski Equipment Golf Clubs Recreation Boats Skates

FRP CONSUMPTION (IN MILLION POUNDS) Source: SPI CI, April 99

FRP - CIVIL STRUCTURES CURRENT FIELD ACTIVITIES Pedestrian Bridges Highway Bridges Seismic Retrofit Columns Bridge Strengthening Bridge Repairs

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

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 5

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

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)

FRP TECHNOLOGY PUBLIC CONCERNS Fire/Flame Resistance Smoke Toxicity Fuel Spills Vandalism/Theft Inspectibility Repairability 11

MANUFACTURING PROCESS COMMON TO CIVIL APPLICATIONS Pultrusion Filament Winding Layup

WHAT IS FRP COMPOSITES COMPONENTS Fiber Reinforcement Resin Matrix ***(Fiber-Matrix Interphases)*** Fillers Additives 9

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

FRP TECHNOLOGY FIBER TYPES Glass Aramid Carbon (Graphite) Boron Polyvinyl alcohol (PVA) (Available in Japan) 11

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)

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

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

FRP TECHNOLOGY ARAMID FIBER Aromatic Polyamides Kevlar 29 Kevlar 49 Anisotropic Materials Linear Elastic to Failure Failure by Rapture

FRP -TYPICAL PROPERTIES Source: Tonen Energy Corp

FRP BRIDGE TECHNOLOGY FIBER PROPERTIES Carbon (600 ksi) 4 Aramid (500 ksi) 3 E-glass (350 ksi) fiber stress (Gpa) 2 1 1 2 3 4 fiber strain (%) 2

FRP TECHNOLOGY RESIN SYSTEM Thermoplastics (melts when heated, solidifies when cooled, no permanent curing) Thermosets (cures permanently by irreversible cross linking at elevated temp.)

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

FRP TECHNOLOGY RESIN TYPES Unsaturated Polyesters Epoxies Vinyl Esters Polyurethanes Phenolics

FRP - RESIN SYSTEM UNSATURATED POLYESTERS - 1 75% Resins Used in USA Condensation Polymerization of Dicarboxylic Acids & Dihydric Alcohols Contains Maleic Anhydride or Fumaric Acid

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

FRP - RESIN SYSTEM EPOXIES Glycidyl Ethers and Amines Customized Properties Limited Workability Sensitive to Curing Agents High Performance High First Cost

FRP - RESIN SYSTEM VINYL ESTERS Good Workability Fast Curing High Performance Toughness Excellent Corrosion Resistance

FRP - RESIN SYSTEM POLYURETHANES Polyisocyanate & Polyol Reaction or Reinforced Injection Molding Process High Performance Toughness Excellent Corrosion Resistence

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

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

FRP TECHNOLOGY FILLER TYPES Calcium Carbonate Kaolin Alumina Trihydrate Mica Feldspar Wollastonite Silica, Talc, Glass

FRP TECHNOLOGY ADDITIVES Improved Material Properties Aesthetics Enhanced Workability Improved Performance

FRP TECHNOLOGY ADDITIVE TYPES Catalysts Promoters Inhibitors Coloring Dyes Releasing Agents Antistatic Agents Foaming Agents

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

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

FRP - DESIGN AVOID ABRUPT THICKNESS Inefficient By Thickness Avoid Stress Risers Consider Stress Flow Consider Load Paths Understand Structural Behavior

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

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

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

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

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

FRP - DESIGN BONDED JOINTS Epoxy Bonded Assemblies Epoxy Bonded Joints Bonded Shear Transfer Strips Plate Bonding Technology Bonded Splices Durability of Joints

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

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

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 11

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 21

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 22