National Academies Press: OpenBook
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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Suggested Citation:"Front Matter." National Academies of Sciences, Engineering, and Medicine. 2003. Bonded Repair and Retrofit of Concrete Structures Using FRP Composites -- Recommended Construction Specifications and Process Control Manual. Washington, DC: The National Academies Press. doi: 10.17226/22034.
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T R A N S P O R T A T I O N R E S E A R C H B O A R D WASHINGTON, D.C. 2004 www.TRB.org NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM NCHRP REPORT 514 Research Sponsored by the American Association of State Highway and Transportation Officials in Cooperation with the Federal Highway Administration SUBJECT AREAS Bridges, Other Structures, and Hydraulics and Hydrology Bonded Repair and Retrofit of Concrete Structures Using FRP Composites Recommended Construction Specifications and Process Control Manual AMIR MIRMIRAN Constructed Facilities Laboratory Department of Civil Engineering North Carolina State University Raleigh, NC IN ASSOCIATION WITH MOHSEN SHAHAWY SDR Engineering Consultants, Inc. Tallahassee, FL ANTONIO NANNI Co-Force America, Inc. Rolla, MO VISTASP KARBHARI University of California, San Diego San Diego, CA

NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed research provides the most effective approach to the solution of many problems facing highway administrators and engineers. Often, highway problems are of local interest and can best be studied by highway departments individually or in cooperation with their state universities and others. However, the accelerating growth of highway transportation develops increasingly complex problems of wide interest to highway authorities. These problems are best studied through a coordinated program of cooperative research. In recognition of these needs, the highway administrators of the American Association of State Highway and Transportation Officials initiated in 1962 an objective national highway research program employing modern scientific techniques. This program is supported on a continuing basis by funds from participating member states of the Association and it receives the full cooperation and support of the Federal Highway Administration, United States Department of Transportation. The Transportation Research Board of the National Academies was requested by the Association to administer the research program because of the Board’s recognized objectivity and understanding of modern research practices. The Board is uniquely suited for this purpose as it maintains an extensive committee structure from which authorities on any highway transportation subject may be drawn; it possesses avenues of communications and cooperation with federal, state and local governmental agencies, universities, and industry; its relationship to the National Research Council is an insurance of objectivity; it maintains a full-time research correlation staff of specialists in highway transportation matters to bring the findings of research directly to those who are in a position to use them. The program is developed on the basis of research needs identified by chief administrators of the highway and transportation departments and by committees of AASHTO. Each year, specific areas of research needs to be included in the program are proposed to the National Research Council and the Board by the American Association of State Highway and Transportation Officials. Research projects to fulfill these needs are defined by the Board, and qualified research agencies are selected from those that have submitted proposals. Administration and surveillance of research contracts are the responsibilities of the National Research Council and the Transportation Research Board. The needs for highway research are many, and the National Cooperative Highway Research Program can make significant contributions to the solution of highway transportation problems of mutual concern to many responsible groups. The program, however, is intended to complement rather than to substitute for or duplicate other highway research programs. Note: The Transportation Research Board of the National Academies, the National Research Council, the Federal Highway Administration, the American Association of State Highway and Transportation Officials, and the individual states participating in the National Cooperative Highway Research Program do not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the object of this report. Published reports of the NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM are available from: Transportation Research Board Business Office 500 Fifth Street, NW Washington, DC 20001 and can be ordered through the Internet at: http://www.national-academies.org/trb/bookstore Printed in the United States of America NCHRP REPORT 514 Project 10-59A FY’01 ISSN 0077-5614 ISBN 0-309-08785-6 Library of Congress Control Number 2003116851 © 2004 Transportation Research Board Price $21.00 NOTICE The project that is the subject of this report was a part of the National Cooperative Highway Research Program conducted by the Transportation Research Board with the approval of the Governing Board of the National Research Council. Such approval reflects the Governing Board’s judgment that the program concerned is of national importance and appropriate with respect to both the purposes and resources of the National Research Council. The members of the technical committee selected to monitor this project and to review this report were chosen for recognized scholarly competence and with due consideration for the balance of disciplines appropriate to the project. The opinions and conclusions expressed or implied are those of the research agency that performed the research, and, while they have been accepted as appropriate by the technical committee, they are not necessarily those of the Transportation Research Board, the National Research Council, the American Association of State Highway and Transportation Officials, or the Federal Highway Administration, U.S. Department of Transportation. Each report is reviewed and accepted for publication by the technical committee according to procedures established and monitored by the Transportation Research Board Executive Committee and the Governing Board of the National Research Council.

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished schol- ars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. On the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and techni- cal matters. Dr. Bruce M. Alberts is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Acad- emy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achieve- ments of engineers. Dr. William A. Wulf is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, on its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Acad- emy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both the Academies and the Institute of Medicine. Dr. Bruce M. Alberts and Dr. William A. Wulf are chair and vice chair, respectively, of the National Research Council. The Transportation Research Board is a division of the National Research Council, which serves the National Academy of Sciences and the National Academy of Engineering. The Board’s mission is to promote innovation and progress in transportation through research. In an objective and interdisciplinary setting, the Board facilitates the sharing of information on transportation practice and policy by researchers and practitioners; stimulates research and offers research management services that promote technical excellence; provides expert advice on transportation policy and programs; and disseminates research results broadly and encourages their implementation. The Board’s varied activities annually engage more than 4,000 engineers, scientists, and other transportation researchers and practitioners from the public and private sectors and academia, all of whom contribute their expertise in the public interest. The program is supported by state transportation departments, federal agencies including the component administrations of the U.S. Department of Transportation, and other organizations and individuals interested in the development of transportation. www.TRB.org www.national-academies.org

COOPERATIVE RESEARCH PROGRAMS STAFF FOR NCHRP REPORT 514 ROBERT J. REILLY, Director, Cooperative Research Programs CRAWFORD F. JENCKS, Manager, NCHRP DAVID B. BEAL, Senior Program Officer EILEEN P. DELANEY, Managing Editor BETH HATCH, Assistant Editor ANDREA BRIERE, Associate Editor NCHRP PROJECT 10-59A PANEL Field of Materials and Construction—Area of Specifications, Procedures, and Practices PAUL V. LILES, JR., Georgia DOT (Chair) ARTHUR P. YANNOTTI, AASHTO Monitor BENJAMIN FOSTER, Maine DOT ISSAM HARIK, University of Kentucky BRIAN MERRILL, Texas DOT THOMAS E. SARDO, Washington Infrastructure Services, Inc., Irvine, CA STEVEN M. SOLTESZ, Oregon DOT DAVID WHITE, Sika Corporation, Lyndhurst, NJ ERIC P. MUNLEY, FHWA Liaison Representative FREDERICK HEJL, TRB Liaison Representative AUTHOR ACKNOWLEDGMENTS The research reported herein was performed under NCHRP Project 10-59 by the Constructed Facilities Laboratory, Department of Civil Engineering, North Carolina State University. SDR Engineering Con- sultants, Inc.; Co-Force America, Inc.; and Professor Vistasp Karbhari of the University of California, San Diego, were subconsultants to the North Carolina State University for this project. Amir Mirmiran, Professor of Civil Engineering and Director of Technical Services at the Constructed Facilities Laboratory of the North Carolina State University, was the principal investigator. The other contributors to this document are Mohsen Shahawy, Presi- dent, SDR Engineering Consultants, Inc.; Antonio Nanni, Presi- dent, Co-Force America, Inc., and V&M Jones Chair Professor of Civil Engineering, University of Missouri, Rolla; and Vistasp Karb- hari, Professor and Chair of Structural Engineering, University of California, San Diego.

This report contains the findings of research performed to develop recommended construction specifications and a construction process control manual for bonded fiber reinforced polymer (FRP) repair and retrofit of concrete structures. The material in this report will be of immediate interest to bridge construction inspectors, general contrac- tors, FRP subcontractors, and FRP and adhesive materials suppliers. The long-term performance of bonded repairs and retrofits of concrete structures using FRP composites is very sensitive to the process by which the FRP material is stored, handled, mixed, applied, and cured. Because of the difficulty in quantifying the relationship between the long-term performance of FRP applications and the construc- tion process, there has been no rational basis for construction specifications to ensure performance as designed. DOTs have depended on composite materials manufacturers to provide construc- tion process control. FRPs were developed for manufactured products, where process- ing could be tightly controlled. Many manufacturers prefer to have their own repre- sentatives provide construction process control. This arrangement has resulted in satisfactory outcomes, but it may not be practical as this technology moves into wide- spread use. The DOTs need to have some means, such as a process control manual, to check the constituent materials and the adequacy of the construction process. The objective of this research was to develop recommended construction specifi- cations and a construction process control manual for bonded FRP repair and retrofit of concrete structures to ensure performance as designed. This research was performed at the North Carolina State University with the assistance of SDR Engineering Con- sultants; Co-Force America, Inc.; and the University of California, San Diego. The report fully documents the research leading to the construction specifications and the process control manual. Generic quality assurance program checklists, which can be modified for specific projects, are provided in the attached diskette. FOREWORD By David B. Beal Staff Officer Transportation Research Board

SECTION I: Final Report I-1 SUMMARY I-3 CHAPTER 1 Introduction and Research Approach 1.1 Background, I-3 1.2 NCHRP Project Statement and Research Tasks, I-4 1.3 Research Approach and Deliverables, I-5 1.4 Applicability of Results to Highway Practice, I-5 1.5 Section I Organization, I-5 I-6 CHAPTER 2 Findings 2.1 Data Collection and Evaluation, I-6 2.2 Relevant Issues, I-9 I-11 CHAPTER 3 Interpretation, Appraisal and Applications 3.1 General Issues, I-11 3.2 Issues Related to Storage and Handling, I-11 3.3 Issues Related to Substrate Repair, I-11 3.4 Issues Related to FRP Repair Systems, I-14 3.5 Issues Related to Inspection, I-15 3.6 Issues Related to Repair of Defective Work, I-15 3.7 Issues Related to Process Control, I-16 3.8 Knowledge Gaps, I-16 I-17 CHAPTER 4 Conclusions, Suggested Research, and Recommendations for Implementation 4.1 Conclusions, I-17 4.2 Suggested Research, I-17 4.3 Recommendations for Implementation, I-19 I-20 REFERENCES SECTION II: Recommended Construction Specifications II-1 1 General 1.1 Scope, II-1 1.2 Definitions, II-1 1.3 Recommended References, II-8 1.4 Tolerances, II-10 1.5 Site Considerations, II-10 1.6 Fire Considerations, II-10 II-10 2 Submittals 2.1 Working Drawings, II-11 2.2 Quality Control/Quality Assurance Plan, II-11 2.3 Qualifications, II-11 II-12 3 Storage, Handling and Disposal 3.1 Storage, II-12 3.2 Handling, II-13 3.3 Clean-Up, II-14 3.4 Disposal, II-14 II-14 4 Substrate Repair and Surface Preparation 4.1 Removal of Defective Concrete, II-14 4.2 Repair of Defective Reinforcement, II-15 4.3 Restoration of Concrete Cross Section, II-15 4.4 Surface Preparation, II-16 II-18 5 Installation of FRP System 5.1 Environmental Conditions for Installation, II-19 5.2 Shoring, II-19 5.3 Equipment, II-20 5.4 Application of Wet Lay-Up FRP Systems, II-20 5.5 Application of Precured FRP Systems, II-23 5.6 Application of Near Surface Mounted FRP Systems, II-24 CONTENTS

5.7 Curing, II-25 5.8 Protective Coating and Finishing, II-26 5.9 Temporary Protection, II-26 II-26 6 Inspection and QA 6.1 Inspection of Materials, II-26 6.2 Daily Inspection, II-27 6.3 Inspection for Fiber Orientation, II-27 6.4 Inspection for Debonding, II-27 6.5 Inspection for Cure of Resin, II-28 6.6 Inspection for Adhesion, II-28 6.7 Inspection for Cured Thickness, II-28 6.8 Load Tests, II-29 6.9 Auxiliary Tests, II-29 II-29 7 Repair of Defective Work 7.1 Repair of Protective Coating, II-30 7.2 Epoxy Injection of Small Defects, II-30 7.3 Patching of Minor Damages, II-31 7.4 Replacement of Large Defects, II-31 II-31 8 Measurement and Payment 8.1 Method of Measurement, II-31 8.2 Basis of Payment, II-32 II-33 9 Cited References SECTION III: Process Control Manual III-1 1 QA Policy and Program Overview 1.1 QA Policy, III-1 1.2 QA—An Overview, III-1 III-1 2 QA Guidelines for Construction Activities 2.1 Responsibilities, III-1 2.2 Preparation of a Project-Specific QA Plan, III-4 III-10 3 Implementing and Monitoring the QA Program 3.1 Implementing the QA Program, III-10 3.2 Monitoring the QA Program, III-10

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TRB’s National Cooperative Highway Research Program (NCHRP) Report 514: Bonded Repair and Retrofit of Concrete Structures Using FRP Composites contains the findings of research performed to develop recommended construction specifications and a construction process control manual for bonded fiber-reinforced polymer (FRP) repair and retrofit of concrete structures.

Report Parts; Section I, Section II, Section III, QAP Forms (MS Word)

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