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TRANSPORTAT ION RESEARCH BOARD WASHINGTON, D.C. 2008 www.TRB.org N A T I O N A L C O O P E R A T I V E H I G H W A Y R E S E A R C H P R O G R A M NCHRP REPORT 609 Subject Areas Bridges, Other Structures, and Hydraulics and Hydrology Recommended Construction Specifications and Process Control Manual for Repair and Retrofit of Concrete Structures Using Bonded FRP Composites Amir Mirmiran FLORIDA INTERNATIONAL UNIVERSITY Miami, FL Mohsen Shahawy SDR ENGINEERING CONSULTANTS, INC. Tallahassee, FL Antonio Nanni CO-FORCE AMERICA, INC. Miami, FL Vistasp Karbhari UNIVERSITY OF CALIFORNIA San Diego, CA A N D Baris Yalim Ahmet Serhat Kalayci FLORIDA INTERNATIONAL UNIVERSITY Miami, FL Research sponsored by the American Association of State Highway and Transportation Officials in cooperation with the Federal Highway Administration
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 Boardâs 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. 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 609 Project 10-59B ISSN 0077-5614 ISBN: 978-0-309-09928-8 Library of Congress Control Number 2008901883 © 2008 Transportation Research Board COPYRIGHT PERMISSION Authors herein are responsible for the authenticity of their materials and for obtaining written permissions from publishers or persons who own the copyright to any previously published or copyrighted material used herein. Cooperative Research Programs (CRP) grants permission to reproduce material in this publication for classroom and not-for-profit purposes. Permission is given with the understanding that none of the material will be used to imply TRB, AASHTO, FAA, FHWA, FMCSA, FTA, or Transit Development Corporation endorsement of a particular product, method, or practice. It is expected that those reproducing the material in this document for educational and not-for-profit uses will give appropriate acknowledgment of the source of any reprinted or reproduced material. For other uses of the material, request permission from CRP. 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 Boardâs 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 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 manufacturersâ names appear herein solely because they are considered essential to the object of this report.
CRP STAFF FOR NCHRP REPORT 609 Christopher W. Jenks, Director, Cooperative Research Programs Crawford F. Jencks, Deputy Director, Cooperative Research Programs Amir N. Hanna, Senior Program Officer Eileen P. Delaney, Director of Publications Maria Sabin Crawford, Assistant Editor NCHRP PROJECT 10-59B PANEL Field of MaintenanceâArea of Specifications, Procedures, and Practices Paul V. Liles, Jr., Georgia DOT (Chair) Arthur P. Yannotti, New York State DOT Richard R. Carter, El Dorado County DOT, CA Benjamin W. Foster, Maine DOT Issam Harik, University of Kentucky, Lexington Brian Merrill, Texas DOT Thomas E. Sardo, Parsons Transportation Group, Irvine, CA Steven M. Soltesz, Oregon DOT David White, Sika Corporation, Lyndhurst, NJ Eric P. Munley, FHWA Liaison Frederick Hejl, TRB Liaison AUTHOR ACKNOWLEDGMENTS The research reported herein was performed under NCHRP Project 10-59B by the Structures and Construction Laboratory in the Department of Civil and Environmental Engineering at the Florida International University. SDR Engineering Consultants, Inc.; Professor Antonio Nanni of the Co-Force America, Inc. and the University of Miami; and Professor Vistasp Karbhari of the University of Cali- fornia, San Diego were the sub-consultants to the Florida International University for this project. Amir Mirmiran, Professor and Chair of the Department of Civil and Environmental Engineering and Director of Structures and Construction Laboratory at Florida International University, was the Principal Investigator. The other contributors to this document are Mohsen Shahawy, President, SDR Engineering Consultants, Inc.; Antonio Nanni, President, Co-Force America, Inc., and Professor and Chair of the Department of Civil, Architectural, and Environmental Engineering at the University of Miami; and Vistasp Karbhari, Professor of Structural Engineering at the University of California, San Diego. Doctoral students who worked on this project were Mr. Baris Yalim and Mr. Ahmet Serhat Kalayci in the Department of Civil and Environmental Engineering at the Florida International University. C O O P E R A T I V E R E S E A R C H P R O G R A M S
This report presents recommended construction specifications to facilitate highway agenciesâ use of bonded fiber-reinforced polymer (FRP) composites for the repair and retro- fit of concrete structures. These specifications cover the construction of FRP systems used as externally bonded or near surface-mounted reinforcement to enhance axial, shear, or flexural strength of a concrete member. These specifications are supplemented by a con- struction process control manual that provides a program for assuring a consistent and uni- form control of quality and regulatory requirements. The material contained in this report will be of immediate interest to engineers, inspectors, contractors, suppliers, and others involved in the repair and retrofit of concrete structures using FRP composites. The long-term performance of repair and retrofit of concrete structures using bonded FRP composites is very sensitive to the process by which the FRP material is stored, han- dled, mixed, applied (including preparation of the underlying concrete surface), and cured. A finished FRP composite is characterized by both its constituent materials and the process by which those materials are formed into a composite; not solely by the constituent mate- rials as is commonly done. Achieving the as-designed properties of FRP composites requires the adherence to specific process control. However, 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 developing construction specifications that will assure the expected performance. Thus, research was needed to investigate such a rela- tionship and develop recommended construction specifications and a construction process control manual for bonded FRP repair and retrofit of concrete structures to assure perfor- mance as designed. NCHRP Project 10-59 and subsequently Projects 10-59A and 10-59B were conducted to address this need. Project 10-59A produced preliminary construction specifications and a construction process control manual that were further examined and enhanced in NCHRP Project 10-59B. Under NCHRP Project 10-59B, âConstruction Specifications for Bonded Repair and Retrofit of Concrete Structures Using FRP Composites,â Florida International University con- ducted an experimental program to investigate the long-term performance of concrete struc- tures that were repaired or retrofitted using bonded FRP composites. The program covered different forms of surface preparation and FRP defects and the range of environmental con- ditions encountered during installation. Results of this investigation were then used (a) to rec- ommend enhanced construction specifications and a process control manual for such repair or retrofit of concrete structures, and (b) to identify threshold values for surface preparation, FRP defects, and environmental conditions during installation. Use of the recommended specifications, manual, and threshold values will help assure performance as designed. F O R E W O R D By Amir N. Hanna Staff Officer Transportation Research Board
The recommended specifications and process manual will be particularly useful to highway agencies because their use will help assure quality and long service life of the repaired or retrofitted structure and reduce maintenance requirements. Their adoption as AASHTO Construction Specifications and Process Manual for Repair and Retrofit of Concrete Structures Using Bonded FRP Composites will further encourage their use and is, therefore, recommended. The agency research report that provides details of the experimental investigation and the research findings supporting the recommended construction guidelines, construction process manual, and threshold values is not published herein. The report is available on TRB website at http://trb.org/news/blurb_detail.asp?id=8718.
1 Chapter 1 Introduction 1 1.1 Problem Statement 1 1.2 Research Objective 1 1.3 Research Approach 2 1.4 Report Organization 3 Chapter 2 Findings 6 Chapter 3 Conclusions 8 References A-1 Attachment A Recommended Construction Specifications B-1 Attachment B Recommended Process Control Manual C-1 Attachment C Research Description and Findings C O N T E N T S
