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Coauthors:
Vijay P.V., P.E., WVU
Hota VS GangaRao, P.E., WVU
John D. Clarkson, P.E., US Army Corps of Engineers
Richard G. Lampo, US Army Corps of Engineers
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INTRODUCTION
Goal is to expand use of Fiber Reinforced
Polymer (FRP) composites in Civil Works
projects. Currently extensively used in
Auto, Aviation, and Marine applications.
Make use where there is a material
property advantage.
Approach is to crawl, walk, and run.
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Known Composite Gates from Innovative WG
Lock Spieringsluis, Netherlands
Golbey Gate Replacement - Composite Miter Gates , France
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BACKGROUND
FRPs have high strength/weight ratio, ductility,
and durability (act as protective members).
FRPs are manufactured as bars, shapes, and
wraps.
FRPs are lightweight, easy to transport and
implement.
FRP wraps are resin saturated and applied on
structures (wet-layup).
FRP wraps act as protective membranes and
inhibit the flow of moisture/air into concrete,
and reduce steel rebar corrosion.
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Preliminary uses of FRP
5
Plastic timbers
Composite Beams in lieu of Timber
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Preliminary uses of FRP
6
Replacing wheels on floating mooring bits with polymer slides.
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Replace Frozen Rollers on Lift Gates at Bankhead Lock & Dam, AL.
The reaction rollers ceased up due to corrosion and drag when gate is raised or lowered. Design a repair using polymer composite glides with no moving parts.
7
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Replace Frozen Rollers on Lift Gates
8
Rollers on lift gates no longer functioning due to corrosion that has caused the bearings to seize up.
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New pads installed
No moving parts
9
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Current Research Projects
Designing and developing FRP composite
wraps, shapes, and components to replace
or rehabilitate:
1. Underwater curable FRP wrapping of
submerged concrete discharge ports.
2. FRP blocks for miter gates.
3. FRP recess filler panels.
4. Abrasion resistant composite coatings.
5. Repair of corroded steel columns of a
concrete bridge deck.
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1- UNDERWATER WRAPPING
Repair water submerged concrete discharge ports with FRP
wraps.
View of discharge ports
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Repair concrete discharge ports at Chickamauga Dam in Tennessee. Structural movement due to alkali aggregate reaction has caused cracks to develop on columns that define the discharge ports. Will repair using polymer mastic grout and composite wrap that cure underwater. Easier and more durable repair than using steel jackets and grout.
12
Cracking concrete columns
Steel repair shell 358 lbs total weight !
Schematic showing discharge ports in lock structure
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1- LAB STUDY AND MATERIALS
Concrete cylinders (4”x8”)- 36
cylinders
Resin impregnated & heat resistant
Aquawrap 142 0C (288 0F).
Perforator tool (Releases curing generated gas buildup)
Stricture banding (Compresses & consolidates Aquawrap)
BP-4 primer
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1-SURFACE PREPARATION & PRIMER APPLICATION
Surface Preparation
Fill cavities with grout.
Abrade protrusions.
Application of BP-4 Adhesive/Primer
Mix BP-4 part B and part A (1:2 by vol).
Apply ~40±5 mils on concrete surface.
Aquawrap Wrapping
Open the pouch and wrap around the concrete by creating
tension (hand-pulling) for desired number of layers.
Apply 2-4 layers of stricture banding over Aquawrap and
perforate with perforator tool. Let it stay for 1-2 hours.
Remove stricture banding and apply final coat of BP-4
primer. Let it cure for 48 hours.
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1- CYLINDER TESTS Concrete cylinders with & without wrap (4”x8”) were
tested under axial compression (ASTM C-39).
Cylinders were capped on both ends with elastomeric
pads to achieve concentric axial loading.
Compression tests on wrapped cylinder
Number of
wraps
Avg. Axial
Strength
KN (lbs)
0 (None) 107 (24139.5)
1 169 (37999.0)
2 214 (48152.7)
3 244 (54869.0)
5 384 (86268.3)
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Wrapped cylinders with 1, 2, 3 and 5 layers of Aquawrap
showed an avg. strength increase of 57.4%, 49.8%, 42.4% and
51.5%, respectively.
Average strength increase per layer was noted to be ~50%.
0
50
100
150
200
250
300
1 layer 2 layers 3 layers 5 layers
57.4
99.5 127.3
257.4
Pe
rce
nta
ge
str
en
gth
in
cre
ase
1- TEST RESULTS AND ANALYSIS
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Repair concrete discharge ports at Chickamauga Lock in Tennessee.
Helper handing diver roll of composite wrapping – much easier than handling 100 lb-plus piece of steel.
Video monitoring of installation – subsequent diving inspection has shown the composite wrap to look like the day it was installed.
1- TWO LAYERS OF WRAP FOR REPAIR
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FRP Composite Miter Blocks for small lock on Washington Lake Canal, WA. Corrosion of steel miter blocks can lead to leakage and gate misalignment.
Corroded steel miter blocks.
Small lock at Hiram Chittenden (Washington Lake Canal) Locks, Seattle, WA.
2- MITER BLOCKS
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Composites designed to resist hydro-static pressure, water-jet knife, and comp. pressure (70 kips/ft length)
Miter block required to withstand
compressive pressure and 12,000
cycles of operation per year
2- CORROSION RESISTANT FRP FOR MITER GATE
BLOCKS (Washington Canal)
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Composite blocks have to resist cyclic loadings and an occasional foreign objects trapped between the blocks during gate closure.
2- FRP COMPOSITE MITER BLOCKS FOR SMALL LOCK ON WASHINGTON LAKE CANAL, WA.
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Group No. of
Variations
Example Load Range
Kips
I 5 Max.
84 kips (with
core)
No-cracking & Group
IV specimen is selected
for field installation.
Specimen provided
~ 51 ksi failure stress.
II 4 Max.
145 kips
III 1 Max. 192 kips (at
deflection limit
of 0.23”)
IV 1 > Max. is 224
kips (UTM limit)
Note: Groups I & II consist of trimmed FRP tubes & plates with foam core or solid square tube cores. Groups III & IV consist of solid FRP sheets and block.
2- FRP MITER BLOCKS (4”X2.5”X2”)
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Pinching Behavior with Foreign Object
2- MITER BLOCK PINCH TESTS
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FRP composite miter blocks selected survived 50 ksi that far exceeds the required 1.4 ksi with no cracking after fatigue load in excess of 500,000 cycles. Scheduled for installation during dewatering in October 2014.
2- FRP COMPOSITE MITER BLOCKS FOR SMALL LOCK ON WASHINGTON LAKE CANAL, WA.
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Existing panel
is requires
difficult and
extensive
welding to
fabricate
10’x12’ steel protection panel
with heavy weight & corrosion
3- RECESS PROTECTION PANEL (LOCKS & DAMS)
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Recess Filler Panels at Willow Island Locks and Dam, Ohio. Steel panels costly, heavy, and they corrode.
Current steel panels
Initial tube and plate design
3- FRP COMPOSITES DEMONSTRATIONS
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Laboratory testing Final design
FRP hex sections with shear keys
Steel channel with curved edges
3- RECESS FILLER PANELS AT WILLOW ISLAND LOCKS AND DAM, OHIO.
Finished DimensionS: 9’10.5”x11’10”
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3- RECESS PANEL WITH FRP SUPERDECK
FRP superdeck required an edge steel frame housing.
Finished panels to be installed Spring of 2014.
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Abrasion - Resistant Overlays for Tainter Gates at Heflin Dam, AL. Swirling debris quickly damages traditionally used vinyl coatings.
Use organic and ceramic composites for overlays
4- FRP COMPOSITES DEMONSTRATIONS
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Profilometer
(1 oA sensitivity)
Samples Coatings Abrasion
Vinyl 3-E-Z
(Current)
~1 mil
500 cycles
ARC 855
Ceramic
Comp.
~0.14 mil
1500 cycles
Vinyl 5-A-Z
~ 0.14 mil
2000 cycles
Tar guard Similar to
3-E-Z -20000
-10000
0
10000
20000
30000
40000
0 200 400 600 800 1000 1200 1400
Ab
ra
de
d S
urfa
ce D
ep
th,
OA
Horizontal Distance on gate plate (µm)
4- ABRASION-RESISTANT COATING SYSTEMS FOR TAINTER GATES
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Reciprocating Abrading Steel Ball System (L) with Computerized Control & Profilometer (R) (Note: the tank will accommodate both securing of specimen and conditioning with liquid)
4- ABRASION - RESISTANT OVERLAYS FOR TAINTER GATES AT HEFLIN DAM, AL.
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Due to scheduling problems, now planning to install these coatings/overlay on a gate along the Arkansas River, Little Rock District.
4- ABRASION - RESISTANT OVERLAYS FOR TAINTER GATES
0
2
4
6
8
10
12
Vinyl 3-a-z, dry
Vinyl 3-a-z, wet
Vinyl 5-e-z, dry
Vinyl 5-e-z, wet
ARC855, dry
ARC855, wet
ARC S2,dry
ARC S2,wet
Vo
lum
e (
mm
3)
5k 10k 25k 50k
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Bring load capacity back to original at 35% of cost using traditional methods. Use composite shell with wrap, and fill with self consolidating concrete (SCC).
5- REHAB OF CORRODED STEEL H-PILES, EAST FORK BRIDGE (1969), HUNTINGTON, WV.
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Significant section loss
Repair design Wrapping the piles with FRP
5- REHAB OF CORRODED STEEL H-PILES, EAST FORK BRIDGE, WV.
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5- FRP SHELL AND WRAP WITH SCC FILLING
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5- BRIDGE OPEN TO TRAFFIC AFTER REHABILITATION
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Underwater wrapping: Strength increase of ~50% per wrap for concrete cylinders. The Aquawrap materials were found to be in original condition
after three months of installation on discharge ports in Chickamauga L&D, TN.
Underwater curable composite wrap – easier and more durable than using steel jackets and grout.
CONCLUSIONS
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FRP miter block: Solid FRP miter block met strength requirements under both the
static and fatigue loads, carrying an average failure stress of 51 ksi (vs. required 1.4 ksi). Additional warping studies are underway. Non-corrosive and better sealing.
CONCLUSIONS
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FRP recess panel: Hexagonal FRP superdeck panel system showed excellent energy absorption characteristics. Steel panels costly, heavy, and they corrode – designed using off-the-shelf products.
CONCLUSIONS
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Abrasion resistant coating: Traditional coatings fail. UHMW-PE plate and ceramic composite coatings performed the best under dry (none) and water immersion abrasion testing.
CONCLUSIONS
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Rehab of Corroded Steel Piles: Conventional fix of welding steel plates only good for 10-15 years. Corroded steel piles were rehabilitated to original load capacity with FRP jackets at 35% of cost using conventional methods.
CONCLUSIONS
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FRP Composite Wicket Gates. Timber wicket gates: rapid deterioration, costly to replace. infrastructure.
Rapid and severe deterioration in traditional wooden wickets. Replacement is costly.
6- FRP COMPOSITES R&D – NEXT STEP
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Building on Success!
Prototype wicket gates will be developed using both thermoset and thermoplastic composites to be installed along the Illinois River, Rock Island District.
Stepping stone to future design and application of other larger FRP composite valves and gates.
Extend the life of new and existing infrastructure.
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Composites will increasingly be utilized in civil works projects. If you have questions or know of other applications please contact: