Fiber Reinforced Polymers (FRP) in infrastructure: Rules and guidance. Liesbeth Tromp Kees van IJselmuijden

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1 Fiber Reinforced Polymers (FRP) in infrastructure: Rules and guidance Liesbeth Tromp Kees van IJselmuijden

2 Who is RHDHV? 2

3 Engineers, Consultants, Architects, FRP team Kees van IJselmuijden (engineer) Joris Smits (architect) Ernst Klamer (engineer) Liesbeth Tromp (FRP specialist) 3

4 FRP Capabilities Royal HaskoningDHV Engineering (including Finite Element Analysis) Architectural Design Feasibility studies Life Cycle Costing Sustainability evaluations (LCA) Second opinion and consultancy Tender documents System based contract management/ Quality Control Royal HaskoningDHV is technical coordinator of national FRP design guidance and partner of FRP Eurocode 4

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6 Why FRP? Low maintenance 10% - 30% lower costs reduced (traffic) hindrance Lightweight and prefab 2 á 3 times lighter than steel Quick installation Renovation and life time extension Cost effective Life Cycle Analyses Replacement of steel structures, lift bridges, 6 moveable structures, temporary structures Sustainable and durable Efficient material usage, low energy usage Long life (> 80 years) Strong MPa Fatigue resistant

7 Applications in infra structure and architecture FRP has demonstrated its value and feasibility a.o. for: Footbridges Traffic deck panels Traffic bridges Moveable bridges Hybrid bridges ( FRP/steel) Renovation (lightweight life time extension) Cladding Edge elements Roof structures 7

8 Footbridges by RHDHV Design by Joris Smits, Royal HaskoningDHV Floating footbridge and incidental vehicles Installed 2011 Design by Jorge Moura, Royal HaskoningDHV Footbridge and incidental vehicles Installed

9 Liftbridge Katwijk Design by Joris Smits, Royal HaskoningDHV Foot bridge and incidental vehicles; span 25m FRP lift bridgedeck, steel balance structure, concrete substructure and approaches Architectural design and engineering by RHDHV (2013) 9

10 Royal Lift bridge HaskoningDHV: Oude Rijn, Katwijk Dragon Fly bridge Ontwerp Jorge Moura, RoyalHaskoningDHV Pedestrian bridge and incidental vehicle Hybrid glass fiber and carbon fiber reinforcement 10

11 FRP traffic bridge and trams : Sint Sebastiaansbridge Delft 34m Engineering by Royal HaskoningDHV 12m Traffic bridge (tender design) 2 moveable decks: FRP deck with steel main beams combined LM1 and tram load (deck 34m by 12m) Heavy traffic and tram load, fatigue analysis Engineering of structures c.a by RHDHV 11

12 Structural Concept 12

13 Results: Thermal analysis Ux (transverse) (1,8mm - -3,4mm) Uy (length) (6,4mm - -20,4mm) Uz (vertical) (22mm - -2,9mm) 13

14 Results Traffic loads: SLS App 41 mm (steel 28 mm) FRP deck Uz < 17, 8 mm Including conversion factors 1,1*1,1*1,1 = 1,33 14

15 Pijlebrug Meppel table bridge 13,6 m by 9 m Province of Drenthe FRP bridge deck 15

16 Elburgerbrug Tender documents 16 System based contract management/design review

17 Mandelabridge Alkmaar Architect Joris Smits (RHDHV) RHDHV Design Review FRP deck 17

18 FRP Cladding Bridges Jeddah Architect Joris Smits and team (RHDHV) Engineering by RHDHV (South Africa, Netherlands) 18 Steel truss bridges 20m 60m FRP Cladding

19 Development of Design Guidance CUR96 FRP Structures in Civil Structures Eurocode FRP 19

20 Team Herziening CUR96 : Toeleveranciers (composiet, materialen): FiberCore Europe Bijl Profielen PPG Teijin Twaron DSM Bostik VKCN (branche organisatie) Groot Composiet Universiteiten / Onderzoeksinstituten Universiteit Twente Technische Universiteit Delft INHolland WMC TNO Aannemers en ingenieursbureaus Heijmans Movares 20 Solico Royal HaskoningDHV Witteveen + Bos CTC Normalisatie Instituten, Consultants CUR NEN TechnoConsult Overheden Rijkswaterstaat Ingenieursbureau Den Haag Ingenieursbureau Rotterdam (GWR) Ingenieursbureau Utrecht COBc

21 1 Eurocode FRP Official members of WG4 Name Presented by MEMBERS WG4 Luigi Ascione UNI, Italy (Convenor) 2 Lone Døjbak Andersen DS, Denmark 3 Andrea Benedetti andrea.benedetti@unibo.it UNI, Italy 4 Jean-François Caron caron@enpc.fr AFNOR, France 5 Miroslav Cerny cerny@hppro.klok.cvut.cz UNMZ, Czeck republic 6 Joäo Ramôa Correia joao.ramoa.correia@ist.utl.pt IPQ, Portugal 7 Patrice Godonou patrice.godonou@angstrom.uu.se SIS, Sweden 8 Eugenio Gutierrez eugenio.gutierrez@jrc.it JRC, Italy 9 Wojcieech Karwowski w.karwowskil.pw.edu.pl Warsaw University of Technology 10 Thomas Keller thomas.keller@epfl.ch SIA, Switzerland 11 Jan Knippers j.knippers@itke.uni-stuttgart.de DIN, Germany 12 IJselmuijden, Kees van kees.van.ijselmuijden@rhdhv.com NEN, The Netherlands 13 Toby Mottram toby.mottram@warwick.ac.uk BSI, UK 14 Matthias Oppe mo@khing.de DIN, Germany 15 Carlo Paulotto carlo.paulotto@acciona.es Acciona, Spain 16 Pawel Poneta p.poneta@mostostal.waw.pl Mostostal Warszawa S.A., Poland 17 Andreas Schleifer andreas.schleifer@din.de DIN, Germany 18 Morten Gantriis Sorensen mgs@fiberline.com DS, Denmark 19 Ioannis Stefanou ioannis.stefanou@enpc.fr AFNOR, France 20 Jon Taby jon.taby@fireco.no SN, Norway 21 Thanasis Triantafillou ttriant@upatras.gr ELOT, Greece 22 Liesbeth 21Tromp liesbeth.tromp@rhdhv.com NEN, The Netherlands 23 Frédéric Waimer f.waimer@itke.uni-stuttgart.de DIN, Germany

22 Eurocode FRP Structure of the Technical Report Preface Chapter 1: General Chapter 2: Basis of Design (Partial Factors Method) Chapter 3: Materials Chapter 4: Durability (UV Radiation; Temperature; Humidity; Static Charge; Fire) Chapter 5: Basis of Structural Design (Modeling of FRP, Behaviour in the case of Fire; Design assisted by Testing) Chapter 6: Ultimate Limit States and Fatigue 22 (Profiles; Plates and Shells; Sandwich Panels) Chapter 7: Servicability Limit States (Deformations; Vibration and Comfort; Damage) Chapter 8: Connections (Bolted and Adhesive Joints) Chapter 9: Production, Realisation, Management and Maintenance

23 Challenges Maturing Technology Variety of Materials Variety of production processes Pultrusion (Vacuum Assisted) RTM Hand lay up Filament winding Different environments Dry Wet dry Wet Temperatures Variety of applications and loading conditions Connections 23

24 Chapter 2 CUR96: Partial factors for the material CUR96 γ M1 - source of material data : γ M =γ M1 * γ M2 Detailed design material data derived from tests on same material and process (γ M1 = from tests, 1.35 from literature ) γ M2 Depending on Manufacturing method and design Verification By coefficient of variation 24

25 Conversiefactoren: klimaatinvloeden, langeduureffecten η c = η ct. η cv. η ck. η cf; Temperatuur 25 Reductie orde 10% Vocht Kruip Reductie nat/droog orde 10%, natte toepassingen 30%. Bij hoge permanente belasting Afhankelijk laminaatopbouw Vermoeiing Reductie van stijfheid, orde 10% Sterkte analyse: UGT toets levensduuranalyse o.b.v. spannings niveau en wisselingen.

26 Lameleigenschappen VVK (bouwstenen) UD Vezel en hars 0/90 Lameleigenschappen: Tabellen Formules (Halpin-Tsai Manera) Laminaateigenschappen: Klassieke laminaten theorie => software CSM (mat) 26

27 Rekenprogramma s materiaaleigenschappen Diverse rekentools beschikbaar tbv bepalen laminaateigenschappen. obv Klassieke laminaten theorie (Classical Laminate Theory) Overzicht zie : Voorbeeld: Kolibri (Lightweight Structures) 27

28 Sterkte van laminaten of lamellen Tsai-Hill (gecorrigeerd) ( Von Mises voor VVK) Houdt rekening met gecombineerde spanningen: 28

29 Sterktetoets CUR96+ (concept) 29

30 Toetsing UGT en BGT Materiaaleigenschappen Karakteristieke waarden uit tabel of testen Toon aan dat ontwerpwaarden worden gerealiseerd Ontwerpwaarden uit testen of methode van partiële factoren Materiaalfactoren Conversiefactoren Analyse methoden Handberekeningen of eindige elementenanalyse Sterkte toets: 30 O.b.v. vereenvoudigd rek criterium (GVK = 1.2%) O.b.v. Tsai-Hill (gecorrigeerd) O.b.v. doorsnede-toets (profielen) Bewijsvoering door testen Materiaaltesten Componenttesten Full scale-test

31 BGT eisen: Comfort van (voet)bruggen Comforteis: maximale versnelling i.p.v. statische doorbuiging L/300. (NEN-EN Nationale bijlage) Stijfheid VVK is relatief laag t.o.v. sterkte. Massa VVK is relatief laag t.o.v. sterkte => veelal eigenfrequentie met bijkomende massa. Demping (vergelijkbaar met beton) Limiet statische doorbuiging? (bijv. incidentele voertuigen) 31

32 Failure modes FRP compression Interlaminaire shear (ILSS) In plane shear Delamination Tensile Bolted connections 32 Bearing (gat-ovalisatie) Netto section failure Shear out Pull out Adhesive connections Peel stresses Shear failure Delaminatie t.g.v. ILSS

33 Chapter 8: Connections Rules for (multi row) bolted connections Geometrical limits Verification of bolted connection for : In plane and out of plane loading Formulas for determination of joint capacity Stress concentration factors Rules for adhesive connections General configurations Verification by tests 33

34 Guidance adhesive connections Prevent progressive collapse Long term properties aging (temperature, moisture, creep, cure, coating) Fatigue (no rules for infra) Analytical (hand or FEA) supported by test data. Test data from previous projects used as proof of principle in design. Tests as part of quality control. Instructions for tolerances, tools and quality control. Climate control, training and supervision by trained specialist in realisation phase! 34

35 Quality Control Expert review Trained personel Tuned to consequence class and level of expertise Proces control: Proces conditions (moisture, temperature, safety) Traceable materials Fiber placement ( fiber straightness) Impregnation (no voids) Cure Quality checks Verification tests materials (design proof and quality control ) imperfections: geometry, voids Inspection and maintenance plan 0-measurement 35 Inspection protocol

36 Quality of pultrudes and material Pultrusion: NEN-EN part 1-3 flatness straightness Production-imperfections Fiber buckling Voids and dry spots Etc. 36

37 EC FRP and CUR96 Technical report FRP draft finished in 2015 Published for comments 2015 via CEN website Technical Report/Specifications development until 2018 Dutch design guide CUR96 finished 2015 English version will be presented in an event in Utrecht by Rijkswaterstaat 37

38 Thank you for your attention! Voor meer informatie over VVK: 38 Liesbeth Tromp