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Carbon Fiber Strands for Prestressed Concrete Piles
H. Celik Ozyildirim, Ph.D., PE. Principal Research Scientist, VCTIR
and
Stephen R. Sharp, Ph.D., PE. Senior Research Scientist, VCTIR
Virginia Concrete Conference: March 8, 2013
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Outline • Corrosion in reinforced concrete structures
– concrete is expected to protect steel. – conventional steel reinforcement can corrode.
• Corrosion resistant reinforcement (CRR) in – conventional concrete: SS, MMFX2, etc. – prestressed concrete: carbon fiber composite
cable (CFCC): corrosion free, examples • Piles with CFCC for a VDOT Bridge: 2 test piles
(completed), 16 production piles in 2013. • Concrete Issues: bond, consolidation, curing
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Corrosion
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Corrosion Resistance in Conventional Concrete
• Low permeability concrete, however, cracks are a problem
• Coated reinforcements: research in Virginia and elsewhere has shown their limitations
5/21/2013 4 Corrosion under coating
Leaking construction joint
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VDOT Approach to Reinforcement Corrosion Resistant Reinforcement (CRR)
• VDOT has discontinued the use of epoxy coated and galvanized bars and adopted CRR in bridge decks.
• All projects advertised after September 1, 2010 shall be with metallic CRR.
Coated Alloyed
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CRR in VDOT
• Past 2 years, VDOT has used about 8.8 million lbs of CRR
• 20% of CRR used was stainless steel.
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I-95 Precast Concrete
Stainless Steel
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Corrosion Resistance in Prestressed Concrete
• Metallic CRR (alloyed, not coated) with mechanical properties (strength, relaxation) meeting the needs of prestressed concrete industry is not commercially available.
• Corrosion free CFCC has been introduced by Tokyo Rope and has been used in excess of 200 structures around the world over the past 2 decades.
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Carbon Fiber Composite Cable (CFCC) Advantages
• Excellent corrosion resistance: high acid and alkali resistance.
• Light weight: about 1/5th of steel weight (SG = 1.5) • Low relaxation loss: nearly same as low relaxation steel. • High tensile strength: equal to that of steel strand. • High tensile fatigue performance: fatigue performance of
CFCC is superior to that of steel strands. • Low linear expansion: coefficient of linear expansion is
about 1/20 of that of steel. • Non magnetic
5/21/2013 8 http://www.iifc-hq.org/proceedings/APFIS_2012/pdf/F1B03.pdf
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Carbon Fiber Composite Cable (CFCC)
• IS CORROSION FREE • Has high strength: 270 ksi • Bond to concrete twice better than steel • Acceptable elongation: 1.5 to 2% • Can be formed into shape: spirals • Is cut by a grinder • Careful handling due to brittle nature
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CFCC - Carbon Fiber Composite Cable: 60% carbon fiber and 40% resin
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Examples from USA First Application
• Bridge Street Bridge, Southfield, Michigan, 2001
• External cable for post-tensioning
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Transverse Longitudinal
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Maine Cable Stayed Bridge 2007
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Examples from Abroad First CFCC Application in a Bridge
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Shinmiya Bridge, Japan 1988 No distress at present time
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Shinmiya Bridge
New Shinmiya Bridge [After-construction 20 years]
Former Bridge [After-construction 20 years]
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Hisho Bridge in Japan 1993
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Both pre-tensioned and post-tensioned with CFCC
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Cable Stayed Bridge in Denmark 1999
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Herning footbridge
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VDOT Project • Nimmo Bridge in Virginia Beach, VA, is under
construction and will contain18 piles with CFCC in place of traditional steel strand and spiral.
• Two of the piles were test piles. • Each pile is 24-in square; piles will be placed in 2 bents,
and there are16 strands per pile
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Test Piles with CFCC
• Two Test piles (76 and 82-ft long) were fabricated during the week of November 12th, 2012 at the Bayshore Concrete Products facility in Cape Charles, VA.
5/21/2013 18 180-ft long bed with steam curing pipes
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End Preparation
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Mesh sheet Braided grip
4-part wedge Evenly push 4-part wedges into chuck barrel
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CFCC Strand Coupled to Steel Strand
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CFCC Steel
Coupler
In one end of the coupler is the CFCC chuck and the other end steel chuck. Couplers staggered.
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Prestressing
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Once stressed it was left overnight. The next morning final preparations for concrete started
Stressed incrementally •5 kips •15 kips •25 kips •34 kips
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Concrete Placement and Consolidation
22 Consolidation with Internal Vibrators
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CFCC Handling: Consolidation
• Internal vibrators with rubber heads
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Piles and Specimens Steam Cured
24 Research Specimens Cured with the Piles
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Curing
• Temperature sensitive • Maximum concrete temperature of the
element same as for the conventional concrete: 190 F
• For couplers to prevent slippage maximum temperature 50 C (122 F)
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Thermocouple
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CFCC strand CFCC Spiral
Plastic tie
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Temperature Matched Cure (TMC)
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Thermocouple wire
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TMC Specimens in the Lab
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Temperature Data
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Fresh Concrete Properties
Test B1 B2 Time sampled 11:25 am 12:10 pm Slump (in) 4.5 6.75 Air content (%) 7.0 6.2 Density (lb/ft3) 138.5 139.4 Concrete temp (F) 60 60
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Hardened Concrete Properties at 28 Days
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Test B1 B2 SpecCompressive Str. (psi) 7,740 7,530 5,000 minSplitting Tensile (psi) 635 635 ----
Permeability 3,226 4,382 ----Permeability w 100F (C) 570 767 1,500 max
Release strength (Spec: 3,500 psi min): at 18 hr B1: 4,200 psi and B2: 4080 psi
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Strands Detensioned
32 Cutting of Steel Strands with a Torch
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CFCC Cut
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Cutting of CFCC Strands with a Cutting Blade
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Pile Removed From Forms
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Piles Lifted from Forms
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Finished Pile
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Bugholes, but no unusual large visible defects
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Conclusion
• Corrosion free CFCC is used successfully in two prestressed piles.
• Concrete is handled carefully using conventional methods (i.e. consolidation with rubber tipped vibrators)
• When steam curing couplers are kept at temperature below 50C (122F) to avoid slippage
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Future Production Piles
• Longer bed (370 ft) for more piles • Self consolidating concrete for improved
workability
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Acknowledgment
• VDOT’s use of CFCC has been possible through close cooperation between the – FHWA – Industry – VDOT Structure and Bridge Division – VDOT Materials Division – VDOT Construction Division – Hampton Roads District – VCTIR.
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Thank you.
Virginia Concrete Conference: March 8, 2013