Master of Science / Department of Civil Engineering / Hani G. Melhem / Fiber Reinforced Polymer (FRP) is a relatively new material used in the field of civil engineering. FRP is composed of fibers, usually carbon or glass, bonded together using a polymer adhesive and formed into the desired structural shape. Recently, FRP deck panels have been viewed as an attractive alternative to concrete decks when replacing deteriorated bridges. The main advantages of an FRP deck are its weight (roughly 75% lighter than concrete), its high strength-to-weight ratio, and its resistance to deterioration. In bridge design, AASHTO provides load distributions to be used when determining how much load a longitudinal beam supporting a bridge deck should be designed to hold. Depending on the deck material along with other variables, a different design distribution will be used. Since FRP is a relatively new material used for bridge design, there are no provisions in the AASHTO code that provides a load distribution when designing beams supporting an FRP deck. FRP deck panels, measuring 6 ft x 8.5’, were loaded and analyzed at KSU over the past 4 years. The research conducted provides insight towards a conservative load distribution to assist engineers in future bridge designs with FRP decks. Two separate test periods produced data for this thesis. For the first test period, throughout the year of 2007, a continuous FRP panel was set up at the Civil Infrastructure Systems Laboratory at Kansas State University. This continuous panel measured 8.5 ft by 6 ft x 6 in. thick and was supported by 4 Grade A572 HP 10 x 42 steel beams. The beam spacing’s, along the 8.5 ft direction, were 2.5 ft-3.5 ft-2.5 ft. Stain gauges were mounted at mid-span of each beam to monitor the amount of load each beam was taking under a certain load. Linear variable distribution transformers (LVDT) were mounted at mid-span of each beam to measure deflection. Loads were placed at the center of the panel, with reference to the 6 ft direction and at several locations along the 8.5 ft direction. Strain and deflection readings were taken in order to determine the amount of load each beam resisted for each load location. The second period of testing started in the fall of 2010 and extended into January of 2011. This consisted of a simple-span/cantilever test set-up. The test set-up consisted of, in the 8.5 ft direction, a simply supported span of 6 ft with a 2.5 ft cantilever on one side. As done previously both beams had strain gauges along with LVDTs mounted at mid-span. There were also strain gauges were installed spaced at 1.5ft increments along one beam in order to analyze the beam behavior under certain loads. Loads were once again applied in the center of the 6 ft direction and strain and deflection readings were taken at several load locations along the 8.5 ft direction. The data was analyzed after all testing was completed. The readings from the strain gauges mounted in 1.5 ft increments along the steel beam on one side of the simple span test set-up were used to produce moment curves for the steel beam at various load locations. These moment curves were analyzed to determine how much of the panel was effectively acting on the beam when loads were placed at various distances away from the beam. Using these “effective lengths,” along with the strain taken from the mid-span of each beam, the loads each beam was resisting for different load locations were determined for both the continuously supported panel and the simply supported/cantilever panel data. Using these loads, conservative design factors were determined for FRP panels. These factors are S/5.05 for the simply supported panel and S/4.4 for the continuous panel, where “S” is the support beam spacing. Deflections measurements were used to validate the results. Percent errors, based on experimental and theoretical deflections, were found to be in the range of 10 percent to 40 percent depending on the load locations for the results in this thesis.

This research project on the campus of Southern Illinois University Carbondale is an extension to the inquiry into the feasibility and reliability of the technology known as Digital Laser Speckle Image Correlation (DiLSIC). This is a hybrid approach of combining two existing technologies. The first being Digital Image Correlation (DIC) which is a nondestructive evaluation commonly used to find displacement, in-plane strain, as well as deformation. The second being the of laser speckle patterns. This hybrid has achieved level of resolution measured to be 3.4μ. DiLSIC increases the application ability of the DIC technique to situations that generally would not be an option to use. DiLSIC needs no artifact speckle patterns to be applied to the specimen as a preparation for nondestructive testing. In DIC testing, the surface of a specimen must artifact speckles applied to the subject surface. Often the application of artifact speckles is not desirable or possible. DiLSIC is an acceptable alternative to the previously discussed industry-wide practice. This method broadens the usage of the DIC technique to situations which previously were not possible. This technology can identify, quantify, and detect the distribution of strain and stress concentrations in composite structures. For this study, a honeycomb-backed glass fiber reinforced polymer (GFRP) panel from a Cessna aircraft exterior luggage door was obtained and a defect panel is created. The panel is constructed with one area containing a repair compliant with manufacturer standardized methods and a repair area is not compliant and consists of multiple incorrect repair steps. An area with no repair is also tested to act as a control for comparison and quantification. The results for the inspected areas showed a linear strain increase in the noncompliant repair. The data plot for the compliant repair showed a trend of following the same basic curve as the no repair area. A verification process follows the DiLSIC testing consisting of using Infrared Thermography, Air-coupled ultrasonic, and white light artifact speckle DIC. These tests show DiLSIC is a viable alternative to the testing that is available in the industry. DiLSIC can detect defect location, size, geometry and map strain to determine the difference between compliant and noncompliant repairs when compared to a base level non-repair area

Carbon fiber-reinforced plastics (CFRPs) have gained widespread popularity as a lightweight, high-strength alternative to traditional materials. The unique anisotropic properties of CFRP make processing difficult, especially using conventional methods. This study investigates laser cutting by ablation as an alternative by comparing two near-infrared laser systems to a typical mechanical machining process. This research has potential applications in the automotive and aerospace industries, where CFRPs are particularly desirable for weight savings and fuel efficiency. First, a CNC mill was used to study the effects of process parameters and tool design on machining quality. Despite high productivity and flexible tooling, mechanical drilling suffers from machining defects that could compromise structural performance of a CFRP component. Rotational feed rate was shown to be the primary factor in determining the axial thrust force, which correlated with the extent of delamination and peeling. Experimental results concluded that machining quality could be improved using a non-contact laser-based material removal mechanism. Laser machining was investigated first with a Yb:YAG fiber laser system, operated in either continuous wave or pulse-modulated mode, for both cross-ply and woven CFRP. For the first time, energy density was used as a control variable to account for changes in process parameters, predicting a logarithmic relationship with machining results attributable to plasma shielding effects. Relevant process parameters included operation mode, laser power, pulse overlap, and cross-ply surface fiber orientation, all of which showed a significant impact on single-pass machining quality. High pulse frequency was required to successfully ablate woven CFRP at the weave boundaries, possibly due to matrix absorption dynamics. Overall, the Yb:YAG fiber laser system showed improved performance over mechanical machining. However, microsecond pulses cause extensive thermal damage and low ablation rates due to long laser-material interaction time and low power intensity. Next, laser machining was investigated using a high-energy nanosecond-pulsed Nd:YAG NIR laser operating in either Q-Switch or Long Pulse mode. This research demonstrates for the first time that keyhole-mode cutting can be achieved for CFRP materials using a high-energy nanosecond laser with long-duration pulsing. It is also shown that short-duration Q-Switch mode results in an ineffective cutting performance for CFRP, likely due to laser-induced optical breakdown. At sufficiently high power intensity, it is hypothesized that the resulting plasma absorbs a significant portion of the incoming laser energy by the inverse Bremsstrahlung mechanism. In Long Pulse mode, multi-pass line and contour cutting experiments are further performed to investigate the effect of laser processing parameters on thermal damage and machined surface integrity. A logarithmic trend was observed for machining results, attributable to plasma shielding similar to microsecond fiber laser results. Cutting depth data was used to estimate the ablation threshold of Hexcel IM7 and AS4 fiber types. Drilling results show that a 2.2 mm thick cross-ply CFRP panel can be cut through using about 6 laser passes, and a high-quality machined surface can be produced with a limited heat-affected zone and little fiber pull-out using inert assist gas. In general, high-energy Long Pulse laser machining achieved superior performance due to shorter pulse duration and higher power intensity, resulting in significantly higher ablation rates. The successful outcomes from this work provide the key to enable an efficient high-quality laser machining process for CFRP materials.

Although Glass Fiber Reinforced Polymer (GFRP) has many potential advantages as reinforcement in concrete structures, the loss in tensile strength of the GFRP reinforcing bar can be significant when exposed to the high alkali environments. Much effort was made to estimate the durability performance of GFRP in concrete; however, it is widely believed the data from accelerated aging tests is not appropriate to predict the longer-term performance of GFRP reinforcing bars. The lack of validated long-term data is the major obstacle for broad application of GFRP reinforcement in civil engineering practices. The main purpose of this study is to evaluate the longer-term deterioration rate of GFRP bars embedded in concrete, and to develop an accurate model that can provide better information to predict the longer-term performance of GFRP bars. In previous studies performed by Trejo, three GFRP bar types (V1, V2, and P type) with two different diameters (16 and 19 mm [0.625, and 0.7 in. referred as #5 and #6, respectively]) provided by different manufacturers were embedded in concrete beams. After pre-cracking by bending tests, specimens were stored outdoors at the Riverside Campus of Texas A&M University in College Station, Texas. After 7 years of outdoor exposure, the GFRP bars were extracted from the concrete beams and tension tests were performed to estimate the residual tensile strength. Several physical tests were also performed to assess the potential changes in the material. It was found that the tensile capacity of the GFRP bars embedded in concrete decreased; however, no significant changes in modulus of elasticity (MOE) were observed. Using this data and limited data from the literature, a probabilistic capacity model was developed using Bayesian updating. The developed probabilistic capacity model appropriately accounts for statistical uncertainties, considering the influence of the missing variables and remaining error due to the inexact model form. In this study, the reduction in tensile strength of GFRP reinforcement embedded in concrete is a function of the diffusion rate of the resin matrix, bar diameter, and time. The probabilistic model predicts that smaller GFRP bars exhibit faster degradation in the tensile capacity than the larger GFRP bars. For the GFRP bars, the model indicates that the probability that the environmental reduction factor required by The American Concrete Institute (ACI) and the American Association of State Highway Transportation Officials (AASHTO) for the design of concrete structures containing GFRP reinforcement is below the required value is 0.4, 0.25, and 0.2 after 100 years for #3, #5, and #6, respectively. The ACI 440 and AASHTO design strength for smaller bars is likely not safe.

This thesis employs a finite element (FE) method for numerically simulating the mechanical response of constituents in a fiber-reinforced polymer (FRP) composite to indentation. Indentation refers to a procedure that subsumes a rigid indenter of specific geometry to impress the surface of a relatively softer material, with a view of estimating its mechanical properties. FE analyses are performed on a two-dimensional simplified microstructure of the FRP composite comprising perfectly bonded fiber, interphase and matrix sections. Indentation response of the constituents is first examined within the context of linearized elasticity. Time-dependent response of the polymer matrix is invoked by modeling the respective constituent section as a linear isotropic viscoelastic material. Furthermore, indentation responses to non-mechanical stimulus, like moisture absorption, is also simulated through a sequentially coupled analysis. A linear relationship describing the degradation of elastic moduli of the individual constituents with increasing moisture content has been assumed. The simulations subsume a point load idealization for the indentation load eventually substituted by indenter tips with conical and spherical profiles. Results from FE analyses in the form of load-displacement curves, displacement contours and stress contours are presented and discussed. With the application of concentrated load on linearly elastic constituents for a given/known degree of heterogenity in the FRP, simulations indicated the potential of indentation technique for determining interphase properties in addition to estimating the matrix-fiber interphase bond strength. Even with stiffer surrounding constituents, matrix characterization was rendered difficult. However, fiber properties were found to be determinable using the FE load-displacement data, when the load-displacement data from experimentation is made available. In the presence of a polymer (viscoelastic) matrix, the surrounding elastic constituents could be characterized for faster loading rates when viscoelastic effects are insignificant. Displacements were found to be greater in the presence of a polymer matrix and moisture content in comparison with a linearly elastic matrix and dry state. As one would expect, the use of different indenter tips resulted in varying responses. Conical tips resulted in greater displacements while concentrated load produced greater stresses. Further it was found that, despite the insignificant effects due to surrounding constituents, analytical (Flamant) solution for concentrated, normal force on a homogeneous, elastic half-plane becomes inapplicable in back calculating the elastic moduli of individual FRP constituents. This can be attributed to the finite domain and the associated boundary conditions in the problem of interest.

The use of fiber reinforced polymers (FRP's) for structural repair or retrofit has increased significantly in the last decade, with adoption for civil infrastructure occurring only in the last 20 years. These products are most often used to increase the capacity of damaged or deteriorated structures. Much research has been performed in the arena of testing of various FRP's bonded to both concrete and masonry substrates, the majority of which focusing on three areas; flexural strengthening, in-plane shear strengthening, and mechanical anchoring. Anchorage is commonly the limiting factor in the application of FRP's, due to the inability of the edge of the polymer matrix to reliably extend beyond a point of zero-interfacial stress. Where interfacial stresses exist and the FRP is terminated localized disbondment often occurs, these localized failures then propagate across the entire bond of the structural system. Various mechanical termination details have been tested to mitigate the potential failure modes near the ends of the fabric. There, however, has been very limited research performed on the behavior of dowels which are installed parallel to the FRP fabric and splayed onto the FRP fabric matrix. In this research the mechanical properties of carbon fiber reinforced polymer (CFRP) dowels with a parallel orientation to uniaxial carbon fabric are experimentally tested to determine the tensile capacity of "dowel to splay" CFRP connections and to discover any dominant failure modes.

This study presents a combined viscoelastic (VE)-viscoplastic (VP) analysis for Fiber Reinforced Polymer (FRP) composites subject to simultaneous mechanical load and conduction of heat. The studied FRP composites consist of unidirectional fibers, which are considered as linearly elastic with regards to their mechanical response, and isotropic polymeric matrix, which shows viscoelastic-viscoplastic response under various stresses and temperatures. Due to the viscoelastic and viscoplastic behavior of the polymeric matrix, the overall FRP composites exhibit a combined time-dependent and inelastic behavior. A simplified micromechanical model, consisting of a unit-cell with four fiber and matrix subcells, is formulated to homogenize the overall heat conduction and viscoelastic-viscoplastic responses of the FRP composites. The micromechanical model is compatible with a displacement based finite element (FE) and is implemented at the Gaussian integration points within the continuum finite elements, which is useful for analyzing the overall time-dependent response of FRP composite structures under various boundary conditions. The Schapery nonlinear integral model combined with the Perzyna viscoplastic model is used to describe the viscoelastic-viscoplastic response of the polymer constituents. An integrated time integration algorithm is formulated at the micromechanics level in order to solve the nonlinear viscoelastic-viscoplastic constitutive model at the matrix subcells and obtain the overall nonlinear response of the FRP. The viscoelastic-viscoplastic micromechanical model is validated usingexperimental data on off-axis glass/epoxy FRP composites available in literature. The overall response of the FRP composites determined from the simplified micromechanical model is also compared with the ones generated from microstructures of FRP with various fiber arrangements dispersed in homogeneous polymer matrix. The microstructural models of the FRP with detailed fiber arrangements are generated using FE. The effects of thermal stresses, due to the mismatches in the coefficient of thermal expansions of the fibers and polymeric matrix, and stress concentrations/discontinuities near the fiber and matrix interfaces on the overall thermo-mechanical deformation of FRP composites are studied using the two micromechanical models discussed above. Finally, an example of structural analysis is performed on a polymeric smart sandwich composite beam, having FRP skins and polymeric foam core with piezoelectric sensors integrated to the FRP skins, undergoing three point bending at an elevated temperature. The creep displacement is compared to experimental data available in literature.

Deterioration of concrete bridge decks has become a serious problem in the past few decades. Fortunately, non-corrosive, light-weight Fiber Reinforced Polymer (FRP) material provides an excellent alternative. More than 117 bridges in the USA have been built or repaired with FRP. In Canada, no FRP bridge deck has been used in the field, yet. However, Wardrop Engineering Inc., Faroex Ltd., and ISIS Canada have successfully designed, manufactured, and patented the filament-wound Glass Fiber Reinforced Polymer (GFRP) bridge deck. Since there is no design code for FRP bridge decks, a finite element method, labeled “L&D”, is proposed in this thesis to help bridge engineers better understand the structural behavior of FRP bridge decks. The L&D method is validated by comparing the analysis results with the experimental results of three filament-wound GFRP bridge decks. This L&D method is also applicable for analyzing FRP bridge decks manufactured by other processes.

Fiber reinforced polymer (FRP) composites have been increasingly used inconcrete construction. This research focused on the behavior of concrete columnsreinforced with FRP bars, or prestressed with FRP tendons. The methodology was basedthe ultimate strength approach where stress and strain compatibility conditions andmaterial constitutive laws were applied.Axial strength-moment (P-M) interaction relations of reinforced or prestressedconcrete columns with FRP, a linearly-elastic material, were examined. The analyticalresults identified the possibility of premature compression and/or brittle-tension failureoccurring in FRP reinforced and prestressed concrete columns where sudden andexplosive type failures were expected. These failures were related to the rupture of FRPrebars or tendons in compression and/or in tension prior to concrete reaching its ultimatestrain and strength. The study also concluded that brittle-tension failure was more likelyto occur due to the low ultimate tensile strain of FRP bars or tendons as compared to steel.In addition, the failures were more prevalent when long term effects such as creep andshrinkage of concrete, and creep rupture of FRP were considered. Barring FRP failure,concrete columns reinforced with FRP, in some instances, gained significant momentresistance. As expected the strength interaction of slender steel or FRP reinforcedconcrete columns were dependent more on column length rather than material differencesbetween steel and FRP.Current ACI minimum reinforcement ratio for steel (pmin) reinforced concretecolumns may not be adequate for use in FRP reinforced concrete columns. Design aidswere developed in this study to determine the minimum reinforcement ratio (pf,min)required for rectangular reinforced concrete columns by averting brittle-tension failure toa failure controlled by concrete crushing which in nature was a less catastrophic and moregradual type failure. The proposed method using pf,min enabled the analysis of FRPreinforced concrete columns to be carried out in a manner similar to steel reinforcedconcrete columns since similar provisions in ACI 318 were consistently used indeveloping these aids. The design aids produced accurate estimates of pf,min. Whencreep and shrinkage effects of concrete were considered, conservative pf,min values wereobtained in order to preserve an adequate margin of safety due to their unpredictability.

Deterioration of concrete bridge decks has become a serious problem in the past few decades. Fortunately, non-corrosive, light-weight Fiber Reinforced Polymer (FRP) material provides an excellent alternative. More than 117 bridges in the USA have been built or repaired with FRP. In Canada, no FRP bridge deck has been used in the field, yet. However, Wardrop Engineering Inc., Faroex Ltd., and ISIS Canada have successfully designed, manufactured, and patented the filament-wound Glass Fiber Reinforced Polymer (GFRP) bridge deck. Since there is no design code for FRP bridge decks, a finite element method, labeled “L&D”, is proposed in this thesis to help bridge engineers better understand the structural behavior of FRP bridge decks. The L&D method is validated by comparing the analysis results with the experimental results of three filament-wound GFRP bridge decks. This L&D method is also applicable for analyzing FRP bridge decks manufactured by other processes.