Michael P. YeeNace Coating Inspector Level 3 #50795

RTConsults PLLCNovember 6, 2014

Cost engineering Using Nonmetallic Construction in Brine and

Corrosive Environments

Introduction & Overview

The problem:

In recent years, our infrastructure systems have been

deteriorating at an increasing and alarming rate

New materials that can be used to prolong and extend the service lives of existing structures ??

Fiberglass Reinforced Plastics (FRP)

Introduction & Overview

What is FRP?

FRP is a composite:

Composite = combination of two or more materials to form a new

and useful material with enhanced properties in comparison to

the individual constituents.

FRPs consist of:1. Fibers

2. Matrix

High-strength fibers

Resin matrix

Introduction & Overview

Commonly used matrices:

Vinylester: fabrication for FRP reinforcing bars

(superior durability characteristics)

Epoxy: strengthening using FRP sheets/plates

(superior adhesion characteristics)

Internal reinforcing applications

External strengthening applications

Physical, mechanical, durability properties of FRPs

ISIS EC Module 8

Overall properties and durability depend on:

The properties of the specific polymer matrix

The fiber volume fraction

(i.e., volume of fibers per unit volume of matrix)

The fiber cross-sectional area

The orientation of the fibers within the matrix

The method of manufacturing

Curing and environmental exposure

Introduction & Overview

Introduction & Overview

Polymer matrix:

As the binder for the FRP, the matrix roles include:

1. Binding the fibers together

2. Protecting the fibers from environmental degradation

3. Transferring force between the individual fibers

4. Providing shape to the FRP component

Introduction & Overview

Fibers:

Provide strength and stiffness of FRP

Protected against environmental degradation by the

polymer matrix

Oriented in specified directions to provide strength

along specific axes (FRP is weaker in the directions

perpendicular to the fiber)

Nexus veil, C glass, etc.

Fiber Orientations

• Isometric materials have equal strength in all directions

• Composites can be lighter weight by not having strength in the directions that it is not needed

• Lay-up still has to have some balance and symmetry

• Planning/Design/Development Cost

• Purchase Cost• Installation Cost• Maintenance Cost• Loss/Wear Cost• Liability/Insurance Costs• Downtime/Lost Business Cost• Replacement/Disposal/

Recycling Cost

Cost Difference/Useful Life

Good/Better/Best Choices?

Service Life 10 years Life 15 years Life 20 years+

Service Rating Oilfield Service ChemicalService/Treatment

ASTM RTP-1 Certified Tanks

Cost to Steel Ratio 1.2 Ratio 1.5 Ratio 2.5 Ratio

• Maintenance requirements/costs• Inspection costs, exterior painting,

interior relining, (CathodicProtection not needed)

• FRP has a useful life of 20 years+ with proper resin selection, design, fabrication, and installation*

• Lightweight (4 times lighter than carbon steel)

• Consistent Flow-> (Hazen-Williams coefficient of 150, instead of ~80 for corroded).

Lifecycle Cost

• Standardization and ability to use high automated procedures.

• Portion Control of resin and glass.

• Cost of Skilled Labor*• Field vs Shop: 30,000

gallon capacity shift

Values of Cost Economies

Manufacturing Methods

• Filament winding and fiber placement– Fiber placement has

greater accuracy

– Fiber placement can wind on less symmetrical and even partially concave mandrels

Manufacturing Methods

• Spray-up– Fibers are chopped, coated with resin and sprayed onto

the mold

Potentially harmful effects for FRP:

Introduction & Overview

Environmental Effects

Physical EffectsMoisture & Marine Environments

Alkalinity& Corrosion

Heat & Fire

Cold & Freeze-Thaw Cycling

Sustained Load:

Creep

Cyclic loading:

Fatigue

Ultraviolet Radiation

POTENTIAL

SYNERGIES

DURABILITY

OF FRPs

• Heating cycles or pressurized cycles.

• Chemicals or environmental exposure.

• Operation downtime or maintenance.

Service Life Conditions

FRP materials are now widely used for reinforcement and

rehabilitation of bridges and other outdoor structures

FRPs have seen comparatively little use in building applications

FRP materials are susceptible to elevated temperatures

Several concerns associated with their behavior during fire or in high

temperature service environments

Extremely difficult to make generalizations regarding high

temperature behaviour

Large number of possible fiber-matrix combinations, manufacturing

methods, and applications

High Temperatures & Fire

Potential problems of FRPs under fire:

High Temperatures & Fire

Internal FRP reinforcement

Sudden and severe loss of bond at T > Tg

External FRP strengthening

Too thin for self-insulating layer, loss of bond at T > Tg

20-60% reduction in strength at 600 ºC

• FRP Tanks can have additives to make it fire retardant.

• ASTM E84 Smoke Test (exposed to fire)

• Cost of addition. lowers risk assessment.

Case Study: Water Treatment/Fire Suppression

Potential for damage due to low temperatures and thermal

cycling must be considered in outdoor applications

Freezing and freeze-thaw cycling may affect the durability

performance of FRP components through:

1. Changes that occur in the behavior of the component materials at

low temperatures

2. Differential thermal expansion

between the polymer matrix and fiber components

between concrete and FRP materials

Could result in damage to the FRP or to the interface

between FRP components & other materials

Cold Temperatures

• Areas where paint coatings were insufficient due to high chloride levels.

• FRP Repair kits used to cover and strengthen areas.

• Lasted longer than coated steel areas.

Case Study: Repairing Steel Structures

• Use only same resin system.• Grind out air pockets for a

good bonding surface.• Have qualified crane/forklift

operators*

Case Study: Repairing Surface Damages

• Comprehensive and descriptive specifications• Detailed system engineering• Qualify experienced GRP manufacturer• Quality control and supervision in engineering, in

the shop and in the field• Quality assurance throughout the process

Lessons Learned* Keys to a Successful Project

“You can expect what you inspect- nothing more.”

- John H. Mallinson

“I prefer a composite bike to a steel one. “

- Michael Yee

• Ashland Industries• Future Pipe Industries• Richard Taraborelli, PE• Belco Industries

Credits