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www.concrete-repairs.co.uk
CRLCONCRETE REPAIRS Ltd
Speaker: Bob Berry
Senior Business Development Manager
www.concrete-repairs.co.uk
CRL-Concrete Repairs Ltd• Multi-discipline refurbishment Contractor• Founded 1954 • Turnover 2008-2009: £27m• Nationwide professional contract service• Largest contract to date £5m• Industry award winning status• Five UK Regional Offices• Abu Dhabi Middle East Regional Office
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Presentation
Structural Strengthening of Reinforced Concrete with
Composite materials
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Content• Background• Materials used• Research• Properties• Design Considerations• Application techniques• Project profiles
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Externally Bonded Reinforcement
Definition. • An Externally Bonded Reinforcement system
increases the load carrying capacity of structural members and hence reduces deflection.
• The tensile stresses induced by imposed loads must be shared by the member and the external reinforcement system.
• These stresses are uniformly transferred from the structural member to the bonded reinforcement by means of a structural adhesive
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Why Composites for Construction?
• Advantages….• lightweight • good specific mechanical properties• good durability• readily formed to complex shapes• ability to tailor mechanical properties• guaranteed mechanical properties• can be manufactured to any length• in-built surface preparation• can be pre-stressed….
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History• Composites are not
something new in• construction. They have
been used for several decades
• used some benefits but not all, e.g. GRP
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Reasons for Strengthening
• Requirements for increased load capacity (e.g. Change of use of regulations)
• Insufficient or incorrectly located reinforcement
• Damage (e.g. Corrosion or impact)• Change of structural form (e.g. Cutting
holes through slabs or removal of supports)
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Strengthening with Composites offers significant benefits to the contractor,
designer and the client/owner.• Increased range of design options• Choice of composite and physical properties• Non corrosive material• Maintenance free solutions• Minimum disruption to the operation of the structure• Ease of handling• Ease of application• No need for expensive access equipment• Ability to strengthen a wide range of structural members• Ability to mould in-situ• Quality controlled manufacture of all components
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Requirements of a strengthening system
• Structural requirements• Dynamic loading• Stiffening• Static Loading• Creep Resistance• Durability
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Requirements of a strengthening system
• Environmental/Exposure requirements• Temperature (extremes & variation)• Moisture• Freeze/thaw• Corrosion• Ultra violet radiation• Fire resistance
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- Flatness of substrate- Quality of substrate- Possibility of ongoing corrosion- State of stress in the element- Future loading requirements
SYSTEM DESIGNCONSIDERATIONS
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Externally Bonded Systems provide solutions for the strengthening of all
types of structure:• Buildings• Bridges• Tunnels• Tanks/Vessels• Multi Storey Car Parks• Marine• Industrial• Water• Power/Nuclear• Blast Containment
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Composite materials Composite materials consist of:consist of:
Fibres Fibres
MatrixMatrix
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Composite elements manufactured through a warm extrusion process in which they are impregnated with epoxy resin while subjected to a tensile stress (Pultrusion)
Less flexible than fabrics they are applicable only on specific types of repair work
Pultrusion process
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Development of carbon technology
Manufactured as a uni-directional continuous-fibresheet, supplied in rolls
• Used for structural reinforcement in Japan for >14 years
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Pultruding Carbon Fibre
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Carbon• Wide range of grades with
different mechanical properties• high strength and stiffness• brittle and fail at low strain levels• negative coefficient of thermal
expansion• electrically conductive• may cause galvanic corrosion
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E-glass
• Low strength and stiffness• low cost• more dense - heavier structures• electrically non-conductive• good corrosion resistance• can be attacked by strong
alkaline solutions
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Bi-directional AR-GLASS fibres
Reinforcement of masonry
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Polymer
Silo
Mixers
Blender Filters
Wash / Neutralise
Spinning
Dryer
Bobbin
Sulphuric Acid
CausticThe Manufacturing Process for Kevlar® Brand Yarn
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Kevlar fabric
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Aramid Kevlar• High tensile strength• high elongation to failure• low density - lightweight
structures• low compressive strength• negative coefficient of thermal
expansion• impact resistance increased• non conductive
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6mm BONDED STEEL PLATE• 6mm bolted plate• 110 kg. dead load• Mechanically lifted
REINFORCED CONCRETE• 1110 kg dead load• Formed and cured
FRP PLATE/SHEET• Thin layer - resin bonded• 1.5 kg dead load• Placed by hand
Comparison of techniques
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Steel plate bonding
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- Additional dead load- Limited plate lengths- Possible future corrosion- Drilling & bolting issues- Longer installation time- Health and safety implications
STEEL PLATE CONSIDERATIONS ...
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Applications
• Architectural• Bridges• Strengthening• Structural• New construction• Applications for developments• Various substrates…only concrete?
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Bridges
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Strengthening / repair
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Application techniques
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Contaminants removal
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Cutting CFRP & Applying Resin Adhesive
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Farm underpass, Great Missenden…vehicle loading to 40 tonnes
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New Moss Lane Cast Iron Bridge
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New Moss Lane Cast Iron Bridge
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Cast Iron Substrates
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Application of plate to cast iron beam
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Harbour City MSCP 4 extra floors, 164 columns strengthened, 10 spaces
taken at one time.
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Application over water
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Haven Bridge, Lincolnshire… vehicle loading to 40 tonnes
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Tay Bridge- Dundee• Condition of the
columns prior to protection using Kevlar.
• *Note the shape of the columns
• Trials carried out first
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Tay Bridge- Dundee• View of completed
column prior to the coating system being applied
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Allders Stores, Croydon & Portsmouth... to facilitate escalator/lift installations
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Kings College Hospital… to carry new floor load
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Beau Sejour Leisure Centre, Guernsey… structural modifications/change of use
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Background to West Burton
Fiddler’s Ferry disaster
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West Burton Power Station• Built in 1960’s• Previous
strengthening with a sprayed mantle using Gunite
• When wind reached 25 knots structure had to be evacuated
• Foundations already pre- stressed
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West Burton Power Station
Shuttering being prepared for concrete ring beam
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West Burton Power Station
Layers of Kevlar applied and smoothed by hand and roller
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West Burton Power Station
Peel ply added to the final coat of wet resin for future coating
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QAFCO-Qatar
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QAFCO- Qatar UAE
1.8mm thick carbon on roll Spacers to determineresin thickness
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QAFCO- Qatar UAE
Resin applied to tower Resin applied to laminate
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QAFCO- Qatar UAE
Carbon held in place whilstcuring Keeping in the shade
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QAFCO- Qatar
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FRP Systems- the futureRods and cables- grids and mats- very
high modulus plates for cast iron structures
RebarRebar
FRP SystemsFRP Systems
GridGridFRP SystemsFRP Systems
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Test Walls Strengthened with AK-60 Laminates
Arena blast test with 4 different types of wall placedequidistant from the charge.
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Solid English Bond Brick Wall Strengthened with AK-60 Kevlar®
Laminates
Outer Face- Blast Side Inner Face
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Brick and Light Weight Block Cavity Wall Strengthened with AK-60 Kevlar®
Blast side Inside face of wall
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English Bond Brick Wall with Rubber Coated Kevlar® Fabric
Blast side of wall Inner face no damage
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Canary Wharf Blast MitigationProtection against terrorism2500m2 of KevlarProved it self after PentagonHigh potential in UK market
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Externally bonded systems provide solutions for all types of strengthening:
• Flexural• Shear• Impact• Blast• Seismic• Stiffening• Deflection• Fatigue• Restraint
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Types of substrates
• Concrete• stone• cast iron• brickwork• steel• timber
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Perceived barriers• specification of materials • costs of materials • design guidance • lack of awareness• fire performance• long-term durability• past experience • environmental ?
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FRP SheetsAdvantages
• lightweight- minimal additional dead load, minimal thickness and flexible
• corrosion resistant- high durability, low maintenance
• ease of installation- cost savings, minimal down-time
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Quality Control
• The UD Fabrics (Certificate of Conformity)
• Tensile properties of fabrics
• Tensile properties of laminates
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Testing properties of KEVLAR® UD fabrics
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Quality Control SystemsBond tests
Tap testTap test Pull testPull test
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Testing of Pultruded carbon onto steel
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Pultruded Kevlar testing on steelFribourg University (CH)
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Pultruded Kevlar testing on steel
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Testing of pultruded carbon onto steel University of Bristol
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Design codes
• MBrace Design Guidelines• BD 84/02• Euro-codes
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Product Selector
*******Blast
*******Seismic
******Impact
******Shear
********Flexure
Wall Strengthening
*****Seismic
*****Impact
*******Shear
*******Flexure
Column Strengthening
******Shear
*******Flexure
Slab Strengthening
*******Shear
*******Flexure
Beam Strengthening
Aramid Fibre WrapGlass Fibre WrapCarbon Fibre WrapCarbon Fibre
Plate
Key* Acceptable** Good*** Excellent
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Useful Documents
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“Fibre composite strengthening is proving to be a cost-effective technique, which can bring great benefits to the owners of structures, chiefly because of the speed of installation, leading to less disruption … “
THE CONCRETE SOCIETY
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“ Whilst the approach is simple, composite strengthening is highly dependent on quality of workmanship. It is vital that an experienced repair contractor, using suitably trained and supervised staff, carries out the work. This is one of the key points identified in the Concrete Society Technical Report, TR57 ... “
THE CONCRETE SOCIETY
www.concrete-repairs.co.uk
- To promote & develop the practice of concrete repair
- To advance technical training & education
- To represent members in common interests
- To improve liaison with professional bodies, authorities & specifiers
CRA WAS ESTABLISHED ...
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- Accredited to ISO 9000 - Conform to the CRA Codes
of practice- Operate in accordance with
contract, relevant British Standards & working practices
- Abide by all current Health &Safety requirements
- Observe the highest standards of business integrity
- Positive commitment to staff training
CRA MEMBERS ARE ...
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• design guidelines• full support• fully trained contractors
FRP Systems…..more than just materials!
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Conclusions
• Polymer composites have found applications in the construction industry
• Polymer composites offer the architect, designer and engineer many advantages over traditional construction materials
• New fibre and resin combinations enable wider product and application range
• Polymer composites have a large part to play in the construction industry and their contribution can only increase in the future
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WHY CRL WHY CRL …………..- Accredited to ISO 9001, 14001,
18001 through an integrated Health & Safety, Environment & QualityManagement System (SHEQ)
-Conforms to the CRA Codes of practice
-Operates in accordance with contract,relevant British Standards &working practices
- Abides by all current Health &Safety requirements
- Observes the highest standards of business integrity
- Positive commitment to staff training- Award winning industry status
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CRL CRL …………..- Accredited to ISO 9001, 14001,
18001 through an integrated Health & Safety, Environment & QualityManagement System (SHEQ)
- Industry accreditation - Conforms to the CRA Codes of
practice- Operates in accordance with - contract, relevant British Standards &
working practices - Abides by all current Health &
Safety requirements- Observes the highest standards
of business integrity- Positive commitment to staff training
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CRL is committed toCRL is committed to……....- Provide a safe & healthy working environment for all
- Total Client satisfaction- Promote & develop the practice of concrete repair & protection
- Advance in house technical training & education
- Liaise with professional bodies, authorities, specifiers & institutions
- Maintain its position as the market leader in this contract discipline
- Innovation & new technology- Continued success by continuous improvement
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Integrated Health & Safety, Environmental & Quality Management system (SHEQ) AccreditedProfessional & Industry Association Membership includes
– The Concrete Society – Concrete Repair Association (CRA)– Corrosion Prevention Association (CPA) – Sprayed Concrete Association (SCA)– British Parking Association (BPA)– Civil Engineering Contractors Association (CECA) – Insulated Render & Cladding Association (INCA)
BBA Approved Contractor. major material suppliersConstructionline, Exor, Archiles, Link Up accreditationHighway Agency, Welsh Assembly Government (WAG), Scottish Executive approved English Heritage registeredInvestors in People accreditedProject Performance Assessment SurveyCHAS Accreditation.
Quality
•
•
•••••
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The secret of success ?
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THANK YOU FOR YOUR ATTENTION
Email: [email protected]: www.concrete-repairs.co.uk
www.crlfacades.co.ukwww.crlsurveys.co.uk
Helpline: 0117 986 8088
South West, South Wales & South Midlands Regional Office