FRP Composites for Retrofitting of Existing Civil Structures

Abstract:
A substantial number of civil engineering structures are more than 30 years old. Whilst they require
continuous maintenance, they also require strengthening due to lack of strength, stiffness, ductility and
durability. Because FRP composites are light-weight and easy to install on site, they are considered to
be the most favoured material in many strengthening applications.
The paper will present the state-of-the-art of the FRP composites for strengthening of existing civil
structures and discusses the behaviour of RC beams strengthened by FRP sheets. Existing techniques
for flexural and shear strengthening, near surface mounting Reinforced Concrete (RC) structures will be
discussed.
Introduction:
There are several situations in which a civil structure would require strengthening or rehabilitation due to
lack of strength (flexure, shear etc.), stiffness, ductility and durability. Some of the common stations where
a structure needs strengthening during its lifespan are:
Seismic retrofit to satisfy current code requirements
Upgrade loading requirements , damage caused by accidents and environmental conditions
Initial design flaws and
Change of usage.
Because FRP composites are light-weight and easy to install on site, they are considered to be the most
favoured material in many strengthening applications. The overall cost of the whole strengthening job
using FRP materials can be as competitive as using conventional materials, in addition to being quick
and easy to handle on site with minimum interruption to use of facility.
In some situations, FRP composites are the only plausible material that could be used for strengthening,
especially in places where heavy machinery cannot gain access or closure of the use is not practical.
Urs Meier and his team at the Swiss Federal Laboratories for Materials Testing and Research (Empa)
began research on the use of carbon FRP composites as external reinforcement for strengthening
structures in the mid 1980s. This was the first worldwide research work in the field of FRP composites
for strengthening.
The comprehensive research work done between 1984 and 1989 (Kaiser 1989), enabled the consequent wide spread use of carbon FRP external reinforcement to strengthen structures. Based on
these developments, the first application of carbon FRPs to strengthen a bridge took place in Lucerne,
Switzerland in early 1990s.Ibach Bridge is a multi_span continuous box bridge, which had done of its
prestressed tendons damaged drilling to install new traffic signals (Meier et al.1992).
Although the material cost of carbon FRPs was several times more than that of steel plates, the fact that
6.2 kg of carbon FRPs could be used in place of 175 kg of steel is sufficient to explain the advantages of
carbon FRPs over steel plates.
A substantial number of bridges on European highways and railways are more than 30 years old. Whilst
they require continuous maintenance, they also require strengthening for increased loads due to heavier
vehicles and traffic volume. Strengthening for upgraded loading is now common in bridge engineering
and a significant portion of funding is spent on this. Since 1999, all bridges in Europe are required to
carry 40 tonne vehicles, and consequently a number of old bridges needed strengthening. The traditional
steel plate bonding to the decks was not viable in some cases due to various reasons including,
significant weight increase, access difficulties and longer construction times. Over 30 bridges and other
structures in the UK have been strengthened during 1997 alone, using about 6km of carbon FRP plates.

Carbon FRP plates or sheets have been used to increase the flexural and shear capacity of decks and
beams of the upgraded bridges.
In mid 1990s, the Highway Agency in UK investigated and later implemented the use of aramid FRP
composite material to increase the resistance of bridge columns that were at risk due to accidental
vehicular impact. Following a successful, trial site applications of column wrapping with FRPs in 1997,
the Highway Agency commissioned the Transport Research Laboratory (TRL) to conduct a series of
tests to establish design rules and guidance , which will be published as a formal standard (TR55 2004).
Sometimes, deficiencies in the initial design have required strengthening with FRP composites in
Germany was carried out during the service life of the bridge. Reportedly, one of the first applications of
bridge strengthening with FRP composites I Germany was carried out to correct a design flaw on a
bridge.
A number of bridges built after the World War II in Germany consisted of pre-stressed concrete multispan construction. These were mostly designed as continuous box girders and the joints were usually at
the points of contraflexure where all the tendons were coupled. Many of these bridges now exhibit cracks at
the joints. The main cause for these cracks is a temperature restraint, which was not taken into account in
the initial design. In combination with other stresses, tensile stresses at the bottom increase and exceed the
concrete tensile strength at the joint. This necessitated repairs on these cracked bridges for which Professor
Rostasy and his colleagues from Braunschweig developed a technique to strengthen such joints with
bonded steel plates. In 1986-87, this method was used for the first time with glass FRP plates on the
Kattenbusch Bridge. The Kattenbusch Bridge was designed as a continuous, multi-span box girder with a
total length of 478m. It consists of 9 spans of 45m and side spans of 36.5m each. There are 10 joints. The
depth of the twin box girder is 2 .7m. The bottom slab of the girder is 8.5m wide. One joint was strengthened
with 20 glass FRP plates. Each plate is 3200 mm long, 150 mm wide and 30 mm thick. Loading tests
performed by Rostasy and colleagues showed a reduction in the crack width of 50% and decrease in the
stress amplitude of 36%,thus extending the fatigue life.
A number of other European countries such as Sweden, Italy, Greece, Poland and Turkey have applied FRP
composites successfully for strengthening their existing structures.
Flexural strengthening of RC structures using FRP Plates and Sheets:
Beams, Plates and columns may be strengthened in flexure through the use of FRP composites bonded to
their tension zone using epoxy as a common adhesive for this purpose. The direction of fibers is parallel to
that of high tensile stresses. Both prefabricated FRP strips, as well as sheet can be applied.
Testing of beams retrofitted with FRP sheets:
Tests have been conducted on beams of different cross sections and steel reinforcements retrofitted with

Fig1.Scheme of typical tested beam

FRP sheets to study the flexural behavior ( Ceroni F et al.,). The cross section dimensions and steel

reinforcement details of different beams are shown in table1.

The external FRP reinforcement consisted of one carbon fiber sheet applied on the bottom of the beam;
the sheet width was equal to 110 mm for beams type A and B and 80 mm for beams type C and D.
Each beam was loaded in four-point bending, with forces located 150 mm from mid span, and the span
length was 1800 mm or 1400 mm. The distances from the supports of the longitudinal unidirectional carbon
fiber sheet were varied.
Table1. Geometrical properties of the beams
Beam

L
(mm)

L1
(mm)

L2
(mm)

As

Ac

A1

1800

28

28

A2

1800

150

28

28

A3

1800

300

200

28

28

A4

1800

2 10

2 10

B2

1800

200

200

2 10

2 10

B3

1800

400

400

2 10

2 10

C1

1800

28

28

C2

1800

400

400

28

28

C3

1800

500

500

28

28

D1

1400

2 10

2 10

D2

1400

200

200

2 10

2 10

D3

1400

200

200

2 10

2 10

Table 1 summarizes the geometric properties of the tested beams. L1 and L2 are the distances from the
supports to the ends of the FRP sheet; As and Ac are steel reinforcement in tension and compression
respectively and L is the clear span of the simply supported element.
Materials:
A maximum aggregate size of 15 mm was used in the concrete. The average compressive strength was
equal to 29 MPa; it was obtained by testing cylinders having diameter equal to 150 mm and height equal
to 300 mm. In order to characterize the steel reinforcement, tensile tests were performed on the bars. The
yielding stress of the f8 and f10 bars was respectively of 590 MPa and 550 MPa, the ultimate tensile
strength was respectively of 690 MPa and 625 MPa. For the external reinforcement, carbon fiber sheets
were bonded using appropriate bicomponent resins. The thickness of the sheets was equal to 0.165 mm;
and manufacturers specifications indicated an ultimate tensile strength of 3430 MPa and an elasticity
modulus of 230000 MPa. For the resins, the values of strength and stiffness, provided by the
manufacturer, are negligible compared to those of the fibers. Before applying the external FRP
reinforcement, the concrete surface was cleaned, sandblasted and treated with a primer.
The load was applied by a mechanical device and recorded by a load cell. A small simply supported

steel

beam was used to load the beam in two points. During each test,strains and displacements were
recorded. Along a lateral face of the beam, horizontal displacements, at five different heights (Fig. 3),
were recorded by LVDT transducers of different gage lengths. Transducers having gage length of 50 mm
were used in order to study the local behavior of the cross section (i.e. cracking and curvature); the
others, with a gage length of 350 mm (transducers t2 and t5), were placed to analyze the average
behavior of the beam along the zone with constant bending moment (average cracking and curvature).
About 30 strain gages were also applied to the FRP sheet. Some of them were located at the ends of the
sheets in order to analyze the bond mechanism in the anchorage zone. Others were placed at mid span
in order to evaluate the curvature of the beam and whether the plane section assumption was valid.
Test Results:
Table2. Experimental Results
Beam

Failure Mode

Fmax
(kN)

(mm)

(MPa)

exp
( %)

A1

Tensile failure of steel

9.6

34.6

A2

Peeling of FRP

18.5

51.7

2650

93

A3

Peeling of FRP

19.2

39.3

2138

100

B1

Concrete Crushing

20.3

25.2

B2

Concrete Crushing

25.8

27.0

1610

27

B3

Concrete Crushing

25.8

24.3

1265

27

C1

Tensile failure of steel

11.8

13.3

C2

Peeling of FRP

17.9

16.7

1258

52

C3

Peeling of FRP

16.1

15.3

946

36

D1

Tensile failure of steel

29.6

9.6

D2

Rupture of FRP

42.1

20.0

3380

42

D3

Peeling of FRP

40.1

15.1

3220

36

Table 2 summarizes the outcomes of the experiments in terms of failure mode, maximum load, Fmax
and deflections under the maximum load,
at ultimate condition,

; the last two columns show the stress level of the sheet

1 , and the increment of the bearing capacity Fmax due to FRP application,

exp. The stress values were determined multiplying the experimental strains, measured by the
strain gauges at the midspan, by the nominal modulus of elasticity of the fibers.
The experimental increase in ultimate strength was very substantial ( about 100% ) for beams type A,
whereas it ranged between 27% and 52% in the other cases. It is strongly dependent on the failure
mode and RC cross sectional properties. Beams type B, characterized by compressive failure of
concrete before strengthening, show the lowest increment of strength. Delamination phenomena can
influence in different ways the ultimate behavior of the beams, depending on the beam typology and

distance of sheet end from the support. For type A beams, peeling of the external reinforcement
occurred when the capacity was already clearly increased, whereas, for type C beams, the longer
distance from the support prevented the increase of the bearing capacity causing the peeling of FRP
sheet at the anchorage.
The values of ultimate stresses,

1 , indicate that the high strength of the external reinforcement can

only be
utilized
the
RC
is
not
concrete
failure of

fully
when
failure of
beams
due to
and the
the

Load (kN )

strengthened beams is not controlled by FRP delamination.

Load (kN)

Figure 2. Experimental load-deflection curves (type A beams)

 (mm)
Figure 3.
Experimental
deflection
curves ( type
beams)

load-

Load (kN)

(mm)

Load (kN)

Figure 4. Experimental load-deflection curves ( type C beams )

(mm)

Figure 5.
load-deflection
D beams )

Experimental
curves ( type

Figures 2 - 5
depict
the
load-deflection
diagrams for
each group of
similar
beams,
comparing
virgin
and
strengthened
elements. It can
also
be
underlined that,
in the case of
type A and C beams, the strengthening caused a change in failure mode. Failure of control beams was in
both cases governed by steel reinforcement with a very ductile behavior, While the application of FRP
resulted in a brittle crisis controlled
by peeling.
However, the external reinforcement did not modify the failure mode of type B beams due to concrete in
compression. Load-deflection curves of type B beams are similar for virgin and upgraded beams, also in
terms of ductility; the increase in bearing capacity is small and post-elastic behavior is characterized by
concrete softening. The U-wrap, used for beam D2, improved the sheet bond and avoided premature failure
(peeling), allowing the FRP laminate to achieve tensile failure and a high ultimate ductility of the beam. This
indicates how an appropriate design could make it possible to obtain a ductile behavior of the RC member,
even though it is strengthened with a linear elastic material up to failure.

Figure 6.Flexural strengthening of concrete girders of a cement

manufacturing building in Poland using CFRP strips.
Shear
of
RC
using FRP
Sheets:

strengthening
structures
Plates
and

Shear
is usually
bonding the

strengthening
provided by
external FRP
reinforcement
on the sides
of the webs
with
the
principal
fibre direction perpendicular or with an angle of e.g. 45 to the member axis. For this purpose
prefabricated L-shaped CFRP (Czaderski et al. 2004) plates were installed for the shear
strengthening of the rump of the Duttweiler bridge in Zurich Switzerland in 2001 (see Figure 3). The L-shaped plates were installed in combination with CFRP strips for flexural
strengthening. Figure - 4 shows placing of carbon fibre fabrics in the shear zone of a bridge
above the railway to Laziska power plant in Poland. The strengthening was carried out in 2003.

Figure6.Placing of CFRP fabrics for shear strengthening of DK

81 bridge above railway to Laziska power plant in Poland

Figure 7. Installation of Prefabricated CFRP L-shaped plates

( shear strengthening ) over already installed CFRP strips for
flexural strengthening.
Near Surface

Mounting

Reinforcement (NSMR):
The externally bonded FRP to RC structures is susceptible to damage from collision, high temperature, fire
and ultraviolet rays. To overcome these drawbacks, Near Surface Mounted Reinforcement (NSMR)
technique has been proposed. Slits are cut into the concrete structure with a depth smaller than concrete
cover. CFRP strips or bars are bonded into these slits. Tests have shown that a higher anchoring capacity
compared with CFRP strips glued onto the surface of a RC structure is obtained. Despite the efficiency of
the NSMR technique, a few applications can be found in Europe, where this technique was applied.
Furthermore, codes and guidelines for this technique are missing.

Figure 8. Flexural strengthening of a concrete deck in the region of

negative bending moment using Near Surface Mounting
Reinforcement (NSMR) technique by cutting a slot in the concrete
deck and placing the CFRP into the slots; industry plant in
Stuttgart,Germany.
Column Confinement:
Confinement is generally applied to members in compression, with the aim of enhancing their load bearing
capacity or, in case of seismic upgrading, to increase their ductility in the potential plastic hinge region. The
confinement in seismically active regions has proven to be one of the early applications of FRP materials in
infrastructure applications.
Confinement may be beneficial in non-seismic zones too, where, for instance, survivability of explosive
attacks is required or the axial load capacity of a column must be increased due to higher vertical loads, e.g.
if new storeys have to be added to an existing building or if an existing bridge deck has to be widened. In
any case, confinement with FRP may be provided by wrapping RC columns with prefabricated jackets or in
situ cured sheets, in which the principal fiber direction is circumferential.

Figure 9. Applicaton of CFRP fabrics on concrete

columns for seismic retrofitting of Reggio Emilia
football stadium in Italy.
Retrofitting
Structures:

of

Masonry

Practical applications in recent years have shown the FRPs as an alternative strengthening material for

10

masonry structures, especially those of considerable historical importance. One of the first research
works worldwide was conducted at Empa, Switzerland (Schwegler 1994). FRP strips and fabrics were
applied to the masonry shear walls in the laboratory using epoxy adhesives. The walls were then tested
under static cyclic loading. It was shown, that the in-plane deformation capacity of the masonry shear
walls after strengthening could be increased up to 300%, if the end of the FRP strips are anchored
properly.
A number of historical buildings especially in Italy, Greece and Portugal were retrofitted applying FRP
composites. Aramid and Glass FRP was applied for restoring the Basilica of St.Francis of Assisi in Italy.
The historical building was severely damaged by earthquakes and aftershocks in September and early
October 1997. Figure 5 shows the retrofitting of one of the masonry towers of the ancient Vercelli castle
in Italy by applying CFRP rods bonded into the space between the bricks. Rods were bonded using
epoxy resin.

Figure 10. Carbon rod bonded into the space between the
bricks as reinforcement, Vercelli Castle, Italy
Conclusion:
The use of FRP in civil and building structures is not uncommon anymore: structures have successfully
been strengthened or retrofitted with FRP materials in many European countries. FRP composites are
readily used for strengthening applications mainly due to the relative ease of installation. Strengthening
with FRP composites have mostly been either the lowest tendered price or the only plausible solution
available. The material costs of the FRP composites are several times more than that of conventional
materials (e.g. steel and concrete). However, the life-cycle cost, including fabrication, application,
protection and projected maintenance costs, is comparable and can be less than that of conventional
materials.
Many engineers believe that FRP composites must be used as a complementary material and not as a
substitute for concrete and steel. FRP composites have significant advantages over conventional
materials in particular situations, but composites cannot replace steel or concrete in every single
application.
Design guidelines and recommendations are essential for the wider use of FRP composites in
strengthening of civil and structural engineering. In the last few year, European engineering institutions
and societies in collaboration with researchers and practitioners in the field, either have developed or
are in the process of developing codes and recommendations for professional engineers.

11

Education of engineers is necessary to reap the full potential and the appropriate use of FRPs. Similarly,
training is vital for people who fabricate and install FRP composites in the construction industry. The
quality of the workmanship is a critical factor and thus specifications must address proper fabrication and
installation criteria for composites.
References
Bakis,C.E., L.C.Bank,et al.(May 2002). Fiber-Reinforced Polymer Composites for Construction-State-ofthe-Art Review. Journal of Composites for Construction: 73-87.
Borri,A., M. Corradi,et al. (April 2002). New Materials for Strengthening and Seismic Upgrading
Interventions. Internatonal Workshop Ariadne 10, Arcchip, Prague, Czech Republic.
Ceroni,F., A.Prota,et al.(2001). Experimental Behaviour of RC Beams Strengthened by FRP sheets,
Proc. Of the International Conference.
Motavalli,M., C. Czaderski( Oct 2007), FRP Composites for Retrofitting of Existing Civil Structures in
Europe: State-of-the-Art Review, Composites&Polycon 2007,Tampa, FL USA.

12