This thesis discusses the development of a new type of fibre-reinforced polymer (FRP) beam for use in civil engineering systems. After a detailed evaluation of the advantages and disadvantages of current FRP beam technology, a different approach is proposed which combines traditional laminates with a novel casting technique. To pre-dimension the beam, the classical beam theory is adapted to allow for FRP materials. The resulting formulae were used to determine critical parameters, such as laminate thickness and location in the cross-section, and core dimensions, and to identify failure modes. Based on the results of this analytical study, a detailed testing program was developed. In addition to classical tests, such as bending, shear, and lateral torsion, the performance of the beam was also examined under particular loading regimes specifically designed to induce local failure modes, such as buckling of the web and bearing failure of the section under concentrated loads. The experimental results revealed very good agreement with the analytical predictions. These results were corroborated by a detailed non-linear finite-element analysis, including core cracking and laminate damage. This analysis, in particular, highlighted the synergy between bending and shear behaviour of the beam. This study has revealed that this new type of FRP beam behaves in a predictable manner. Furthermore, the experimental results verified that the cross-section, which combines traditional laminates with cast polymer concrete, did not suffer from many of the disadvantages identified in current FRP beams. The cracking of the polymer concrete under shear, however, does cause the beam to fail prior to the laminates reaching their ultimate shear stress.

Applying lateral confinement to concrete columns using fibre-reinforced polymer (FRP) composites is a very promising technique. FRP rupture is the typical failure mode of FRP wrapped columns under axial compression. numerous experiments have shown that the FRP rupture strain in an FRP wrapped circular column is significantly lower than the FRP ultimate rupture strain determined from flat coupon test of FRP. Despite a large number of studies on the application of FRP confined columns, the mechanisms and level of lower-than-apparent FRP rupture strain still remain unclear. This thesis presents theoretical, Numerical and experimental studies aiming at developing a deeper understanding of the fundamental mechanisms of this phenomenon. A comprehensive literature review was presented providing the background on FRP confined columns, material properties of FRP composites as well as some factors which may lead to premature FRP rupture. A FE analysis was conducted to investigate the FRP hoop strains in the split-disk test, explaining for the first time that the fundamental mechanism of the lower FRP rupture strain in the split-disk test than in the flat coupon test is because strain localisation due to geometric discontinuities at the ends of the FRP and bending of the FRP ring at the gap due to change of curvature caused by the relative moment of the two half disks, as the FRP (as a brittle material) ruptures once the maximum strain at one of these locations reaches the FRP rupture strain. A list of contributory factors affecting the apparent FRP rupture strain in FRP wrapped columns were next identified and classified. An analytical solution was developed to investigate the influence of the triaxial stress state on the FRP strain efficiency, this factor has been shown to have a potentially significant effect on the failure of the FRP wrap but considerable discrepancies exist between predictions using different failure criteria so further research has been identified in this area. FE models were developed to examine the effect of the geometrical discontinuities on the strain efficiency of FRP jackets in FRP wrapped concrete-filled circular steel tubes and FRP wrapped concrete columns. It is demonstrated that severe FRP hoop strain concentrations occur in very small zones near the ends of the FRP wrap in both types of FRP wrapped columns, leading to premature FRP rupture and thus lower strain efficiency. The combined effects of end constraint and FRP overlap on the behaviour of FRP wrapped concrete columns was investigated using a three dimensional FE model considering one half of the length of an FRP-wrapped concrete cylinder. The results have shown that the frication between both ends of a column and the loading platens provides constraints to the ends of the column, but this constraint has little effect on the strain concentration caused by the geometrical discontinuities of the FRP overlap, though the ultimate axial strain of the FRP wrapped columns can be significantly overestimated if the end constraints are not considered.

<div>Research has shown that many adjacent box beam bridges in Indiana experience premature deterioration. Primarily caused by leaking joints between beams, this deterioration leads to corrosion and/or fracturing of prestressing strands, ultimately resulting in flexural deficiency of the bridge. A testing program was designed to simulate this observed deterioration by constructing test specimens and implementing various strengthening techniques using fiber reinforced polymer (FRP) systems. The objective of this testing program is to investigate the effectiveness of FRP strengthening systems to increase or even regain the full capacity of beams that have effectively lost tension reinforcing steel due to corrosion. The FRP-strengthened beam specimens incorporate the use of near-surface-mounted and externally bonded systems. Reinforcing bars in the beams are excluded or cut to simulate deterioration. Furthermore, two different methods of end anchorage for the externally bonded sheets, FRP fan anchorage and U-wrap anchorage, are investigated. Results and conclusions from the testing program are described in order to help advise best practices in implementing the aforementioned strengthening systems. </div>

Although fiberglass reinforced polyester manholes and wetwalls have been proven by the American Society for Testing Materials (ASTM) and are currently being used in some parts of the world, there still exists a lack of investigation for testing manhole covers made with different inorganic fillers under static and dynamic behavior. The filler would not only improve the mechanical properties of fiber-reinforced polymer matrix composite not otherwise achieved by the resin ingredients alone but also lower the overall manufacturing costs by decreasing the amount of fiber content without adversely affecting the composite’s mechanical properties. The main objective involved the development of fiberglass laminated manhole covers with different inorganic fillers and to study the static and dynamic behavior of the material by performing experimental and numerical analysis. The materials used for the composite laminated test specimens consisted of E-glass woven roving fabric, epoxy, and filler. Two types of inorganic fillers were used for this study, calcium carbonate and high-density adhesive fillers. The static/dynamic test results showed that the laminates made with fiberglass and filler experienced lower performance in tensile strength but higher improvement in flexural strength. The modal analysis results showed that laminates with less filler experienced higher modes within the specified frequency range. This was expected since the material property of filler increased the stiffness and damping behavior in the composite material.

Two 7" deep FRP deck panels were manufactured and tested in a controlled service environment. The deck panels were 15' by 5' in plan, and were composed of ten 15' long, 6" by 6" by 3/8" standard pultruded FRP tubes. The tubes were sandwiched between two 3/8" thick standard pultruded FRP plates. The material constituents of the FRP were E-glass fibers in a polyester matrix. When subjected to two strength tests, the first deck panel exhibited a safety factor with respect to legal truck loads of greater than 10. The second deck was subjected to AASHTO design loads, and under a simulated HS-25 axle plus impact the deck exhibited a maximum deflection of L/470. Upon completion of the laboratory testing, the second deck was placed in the field for further study. The maximum strain recorded during field testing was approximately 600 microstrain, which is less than 15% of the ultimate tensile strain of the FRP in its weakest direction. After being subjected to approximately 4 million load cycles (assuming 100,000 5-axle truck crossings per month) over a period of 8 months, the deck exhibited no loss in stiffness. In two post-service strength tests, the second deck exhibited a safety factor with respect to legal truck loads of greater than 8 and greater than 13. / Master of Science

This thesis presents research completed on the experimental performance of two 6 3/4 in thick bridge deck panels fabricated by the Stongwell Corporation of Bristol, Virginia. The panels are made of off-the-shelf, pultruded glass fiber-reinforced polymer elements, bonded and mechanically fastened together. The testing involved laboratory stiffness tests performed on one deck panel which afterwards, was placed in a field test site at the I-81 Troutville Weigh Station facility. The daily truck traffic over the deck panel at this site is approximately 5400 vehicles. The second deck panel was constructed as a prototype to test benefits of steel thru-rod mechanical connectors. Further, a rubber tire loading patch was developed for the laboratory stiffness and strength tests performed on this second specimen to investigate modes of failure. Both decks made use of a hook bolt type connection to steel support beams in order to reduce damage seen in previous methods of connection. / Master of Science

The primary objective of this project was to test a full-scale prototype of an actual bridge deck containing GFRP bars as the top mat of reinforcement. The purpose of the tests was to verify that the design would resist the loads for which it was designed and provide assurance that the deck would not unexpectedly fail due to the use of this new material. Behavior of the bridge and deck, such as failure load, failure mode, cracking load, crack widths, deflections, and internal stresses, were examined. Four tests were performed on the deck, all of which tested the deck in negative moment regions. From the tests, it was concluded that the design of the deck was very conservative and that unexpected failure should be of no concern. The secondary objective of this project was to comment on the construction of a bridge deck reinforced with GFRP bars and to note its advantages and disadvantages along with a critique of the current state-of-the-art of designing bridge decks with FRP reinforcement. It was found that the advantages of construction with GFRP bars far outweighed the disadvantages, and that the placing of the top mat of GFRP bars was much easier than the placing of the bottom mat of steel bars. It was also concluded that the current state-of-the-art of designing bridge decks reinforced with GFRP is, for the most part, inaccurate in its prediction of behavior and that more research is needed to create more accurate design equations and procedures. Although current methods do not result in accurate predictions of behavior, they do, as mentioned above, result in conservative designs. / Master of Science

La détérioration des infrastructures au Canada due à la corrosion des armatures est l'un des défis majeurs de l'industrie de la construction. Les progrès récents dans la technologie des polymères ont conduit au développement d'une nouvelle génération de barres d'armature à base de fibres renforcées de polymères (PRF), (en particulier les fibres de verre). Ces barres, résistant à la corrosion, ont montré un grand potentiel d'utilisation pour mieux protéger les infrastructures en béton armé contre les effets dévastateurs de la corrosion. Avec la publication du nouveau code S807-10 "Spécifications pour les polymères renforcés de fibres" et la production de barres en PRF de très haute qualité, celles-ci représentent une alternative réaliste et rentable par rapport à l'armature en acier pour les structures en béton soumises à de sévères conditions environnementales. La conception des éléments en béton armé de barres en PRF est généralement gouvernée par l'état de service plutôt que l'état ultime. Par conséquent, il est nécessaire d'analyser les performances en flexion et le comportement en service en termes de déflexion et de largeur de fissures des éléments en PRF sous charges de service et de vérifier que ces éléments rencontrent les limites des codes. Aussi, de récents développements dans l'industrie des PRF ont conduit à l'introduction des barres en PRF avec des configurations de surface et des propriétés mécaniques différentes. Ces développements sont susceptibles d'affecter leur performance d'adhérence et, par conséquent, la largeur des fissures dans les éléments en PRF. Cependant, les codes de conception et les guidelines de calcul fournissent une valeur unique pour le coefficient d'adhérence (k[indice inférieur b]) en tenant compte des configurations de surface et en négligeant le type de barre en PRF, le diamètre de la barre, et le type de béton et de sa résistance. En outre, le code canadien S807-10 "Spécifications pour les polymères renforcés de fibres" fournit une étape en classant les barres en PRF par rapport à leur module d'élasticité (E[indices inférieurs frp]). Ces classifications ont été divisées en trois classes : Classe I (E[indices inférieurs frp]<50 GPa), Classe II (50 GPa [plus petit ou égal] E[indices inférieurs frp]< 60 GPa) et Classe III (E[indices inférieurs frp] [plus grand ou égal] 60 GPa). Ce programme de recherche vise à étudier expérimentalement le comportement en flexion des éléments en béton en service armé avec différents paramètres sous charges statiques. Le programme expérimental est basé sous plusieurs paramètres, dont les différents ratios de renforcement, différents types de barres (différentes classes comme classifiées par le CAN/CSA S807-10), le diamètre et la surface de la barre, la configuration ainsi que la résistance du béton. De plus, les recommandations actuelles de design pour les valeurs de k[indice inférieur b] et la vérification de la dépendance des valeurs de k[indice inférieur b] sur le type de barres (verre ou carbone), le diamètre des barres et le type de béton et sa résistance ont été étudiées. Le programme expérimental comprenait la fabrication et les essais sur 33 poutres à grande échelle, simplement appuyées et mesurant 4250 mm de long, 200 mm de large et 400 mm de hauteur. Vingt et sept poutres en béton ont été renforcées avec des barres en PRF à base de verre, quatre poutres en béton ont été renforcées avec des barres de PRF à base de carbone, et deux poutres ont été renforcées avec des barres en acier. Toutes les poutres ont été testées en flexion quatre points sur une portée libre de 3750 mm. Les paramètres d'essai étaient: le type de renforcement, le pourcentage d'armature, le diamètre des barres, configurations de surface et la résistance du béton. Les résultats de ces essais ont été présentés et discutés en termes de résistance du béton, de déflection, de la largeur des fissures, de déformations dans le béton et l'armature, de résistance en flexion et de mode de rupture. Dans les trois articles présentés dans cette thèse, le comportement en flexion et la performance des poutres renforcées de barres en PRFV et fabriquées avec un béton normal et un béton à haute performance ont été investigués, ainsi que les différentes classes de barres en PRFV et leurs configurations de surface. Les conclusions des investigations expérimentales et analytiques contribuent à l'évaluation des équations de prédiction de la déflection et des largeurs de fissures dans les codes de béton armé de PRF, pour prédire l'état de service des éléments en béton renforcés de PRF (déflection et largeur de fissures). En outre, à la lumière des résultats expérimentaux de cette étude, les équations de service (déflection et largeur des fissures) incorporées dans les codes et guidelines de design [ACI 440.1R-06, 2006; ISIS Manual No.3, 2007; CAN/CSA-S6.1S1, 2010; CAN/CSA-S806, 2012] ont été optimisées. En outre, les largeurs de fissures mesurées et les déformations ont été utilisées pour évaluer les valeurs courantes de k[indice inférieur b] fournies par les codes et les guidelines de calcul des PRF. En outre, les conclusions ne prennent pas en charge la valeur unique de k[indice inférieur b] pour les barres en PRF de types différents (carbone et verre) avec des configurations de surface similaires et s'est avéré être dépendant du diamètre de la barre.

In this study, a total of twelve beams continuous over two spans of 2,800 mm each were constructed and tested to failure. The beams were divided into two series. Series 1 included six T-beams under symmetrical loading, while Series 2 dealt with six rectangular beams under unsymmetrical loading conditions. In Series 1, the test variables included material type, assumed percentage of moment redistribution, spacing of lateral reinforcement in flange, arrangement of shear reinforcement, and serviceability requirements. In Series 2, three different loading cases were considered, I) loading both spans equally, II) loading both spans maintaining a load ratio of 1.5 and III) loading one span only. Under the loading case II, the parameters of reinforcing material type, assumed percentage of moment redistribution and serviceability requirements were investigated. The test results of both series showed that moment redistribution from the hogging to the sagging moment region took place in GFRP-RC beams which were designed for an assumed percentage of moment redistribution. In Series 1, the decrease of the stirrups spacing from 0.24d to 0.18d enhanced the moment redistribution percentage. Also, decreasing the spacing of lateral reinforcement in the flange from 450 to 150 mm improved the moment redistribution through enhancing the stiffness of the sagging moment region. In Series 2, the unsymmetrical loading conditions (loading case II and III) reduced the moment redistribution by reducing flexural stiffness in the heavily loaded span due to extensive cracking. Regarding serviceability in both series, the GFRP-RC beam designed for the same service moment calculated from the reference steel-RC beam, was able to meet the serviceability requirements for most types of the structural applications. / February 2017

Excellent properties of Carbon Fiber Reinforced Polymer (CFRP) composites are usually obtained in the direction at which carbon fibers are embedded in the polymeric matrix material. The outstanding properties of this material such as high strength to weight ratio, high stiffness and high resistance to corrosion can be tailored to meet specific design applications. Despite their excellent mechanical properties, application of CFRPs has been limited to more lucrative sectors such as aerospace and automotive industries. This is mainly due to the high costs involved in manufacturing of this material. Machining, milling and drilling, is a critical part of finishing stage of manufacturing process. Milling and drilling of CFRP is complicated due to the inhomogeneous nature of the material and extreme abrasiveness of carbon fibers. This is why CFRP parts are usually made near net shape. However, no matter how close they are produced to the final shape, there still is an inevitable need for some post machining to obtain dimensional accuracies and tolerances. Problems such as fiber-matrix debonding, subsurface damage, rapid tool wear, matrix cracking, fiber pull-out, and delamination are usually expected to occur in machining CFRPs. These problems can affect the dimensional accuracy and performance of the CFRP part in its future application. To improve the efficiency of the machining processes, i.e. to reduce the costs and increase the surface quality, researchers began studying machining Fiber Reinforced Polymer (FRP) composites. Studies into FRPs can be divided in three realms; analytical, experimental and numerical. Analytical models are only good for a limited range [0° – 75°] of Fiber Orientations , to be found from now on as “FO” in this thesis. Experimental studies are expensive and time consuming. Also, a wide variety of controlling parameters exist in an experimental machining study; including cutting parameters such as depth of cut, cutting speed, FO, spindle speed, feed rate as well as tool geometry parameters such as rake angle, clearance angle, and tool edge/nose radius. Furthermore, the powdery dust created during machining is known to cause serious health hazards for the operator. Numerical models, on the other hand, offer the unique capability of studying the complex interaction between the tool and workpiece as well as chip formation mechanisms during the cut. Large number of contributing parameters can be included in the numerical model without wasting material. Three main objectives of numerical models are to predict principal cutting force, thrust force and post-machining subsurface damage. Knowing these, one can work on optimization of machining process by tool geometry and path design. Previous numerical studies mainly focus on the orthogonal cutting of FRP composites. Thus, the existing models in the literature are two-dimensional (2D) for the most part. The 2D finite element models assume plain stress or strain condition. Accordingly, the reported results cannot be reliable and extendable to real cutting situations such as drilling and milling, where oblique cutting of the material occurs. Most of the numerical studies to date claim to predict the principle cutting forces fairly acceptable, yet not for the whole range of fiber orientations. Predicted thrust forces, on the other hand, are generally not in good agreement with experimental results at all. Subsurface damage is reported by some experimental studies and again only for a limited FO range. To address the lack of reliable force and subsurface damage prediction model for the whole FO range, this thesis aims to develop a 3D finite element model, in hope of capturing out-of-plane displacements during stress formation in different material phases (Fiber, Matrix and the Interface bonding). ABAQUS software was chosen as the most commonly used finite element simulation tool in the literature. In present work a user-defined material subroutine (VUMAT) is developed to simulate behavior of carbon fibers during the cut. Carbon fibers are assumed to behave transversely isotropic with brittle (perfectly elastic) fracture. Epoxy matrix is simulated with elasto-plastic behavior. Ductile and shear damage models are also incorporated for the matrix. Surface-based cohesive zone technique in ABAQUS is used to simulate the behavior of the zero-thickness bonding layer. The tool is modeled as a rigid body. Mechanical properties were extracted from the literature. The obtained numerical results are compared to the experimental and numerical data in literature. The model is capable of capturing principal forces very well. Cutting force increases with FO from zero to 45° and then decreases up to 135°. The simulated thrust forces are still underestimated mainly due to the fiber elastic recovery effect. Also, the developed 3D model is shown to capture the subsurface damage generally by means of a predefined dimensionless state variable called, Contact Damage (CSDMG). This variable varies between zero to one. It is stored at each time step and can be called out at the end of the analysis. It was shown that depth of fiber-matrix debonding increases with increase in FO. / Graduate