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High Performance Fiber Reinforced cement-based
Composites
PEER Annual Meeting
Sept 30-Oct1, 2011
Civil and Environmental Engineering Department
University of California, Berkeley, CA 94720
Claudia P. Ostertag1 and Sarah Billington2
1CEE Department, University of California, Berkeley 2CEE Department, Stanford University
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I. Future Challenges II. Characteristics of High Performance Fiber
Reinforced cement-based Composites (HPFRCCs)
III. Damage Resistance of Bridge Structures due to HPFRCCs
IV. Reservations/Concerns towards HPFRCCs V. Summary
Outline
Civil and Environmental Engineering Department, University of California, Berkeley, CA 94720
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Structures need to be safe under seismic loading conditions
And in addition: I. Structures need to be damage resistant to
reduce repair cost II. Structures need to last longer to enhance their
service life III. Structures need to be sustainable hence
preserve our resources & have low carbon foot print
I) Future Challenges
Civil and Environmental Engineering Department, University of California, Berkeley, CA 94720
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Problems with many current bridge structures: Deterioration
Example #1: Bridge Columns
Deterioration caused by
both environmental and seismic loading
conditions.
Environmental Damage (Corrosion)
Seismic Damage
(ASR)
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Problems with many current bridge structures: Deterioration
Example #2: Bridge Approach Slabs
Cracks = Reduced Flexural Stiffness and Durability
Washout and Traffic Loading
Subsidence
Plastic/Drying Shrinkage
Spalling from Rebar Corrosion and Frost Damage
Deterioration due to both mechanical and environmental loading conditions
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The use of High Performance Fiber Reinforced Cement-based Composites in Concrete Structures for
• Higher Damage Resistance when exposed to both seismic and environmental loading conditions
• Extended Service Life and more Sustainable Structures
• Enhanced Performance
Effective Solution
Civil and Environmental Engineering Department, University of California, Berkeley, CA 94720
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II) Characteristics of High Performance Fiber-Reinforced cement based Composites
Deflection hardening
Example: Hybrid fiber reinforced concrete composite (HyFRC)
Flexure beams: 6”x6”x28” Vf=1.5vol%
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Conventional FRC Dominant crack forms at same load level as in
plain concrete
Concrete and Conventional FRC
∆
P
P Dominant macrocrack formation
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HPFRC
HyFRC
∆
P
B @ Point
A
B
P Delay in macrocrack formation
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II) Characteristics of High Performance Fiber-Reinforced cement based Composites
0.00.51.01.52.02.5
0.00 0.01 0.02 0.03 0.04Tensile Strain
Tens
ile S
tres
s (M
Pa)
ECC
Mortar
FRC
0.00.51.01.52.02.5
0.00 0.01 0.02 0.03 0.04Tensile Strain
Tens
ile S
tres
s (M
Pa)
ECC
Mortar
FRC
Tension hardening
Example: Engineered Cementitious Composite (ECC)
10 mm
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Examples of HPFRCCs that have been used for structural applications
ECC: mortar matrix without coarse aggregate, 2 vol% PVA fiber (developed by Prof. Li at University of Michigan) HyFRC: concrete matrix with 9.5mm coarse aggregates, 1.5 vol% fibers (developed by Prof. Ostertag at UC Berkeley)
•1st generation of HyFRC: Bridge Approach Slabs for Area III (CalTrans) •2nd generation of HyFRC: Self-compacting HyFRC: Bridge Columns (PEER) •3rd generation of HyFRC: Service Life Enhancement and Reduction in Carbon Footprint of Highway Structures (FHWA)
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III) Damage Resistance of bridge structures due to HPFRC
Example #1: Precast ECC segmental bridge piers (Billington) Example #2: Bridge columns with Self-compacted HyFRC (SC-HyFRC); (PEER: Ostertag & Panagiotou) Example #3: Bridge Approach slabs in Area III with HyFRC (CalTrans: Ostertag)
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(Rouse, 2003; Billington & Yoon, 2004; Lee & Billington, 2008)
Example #1 Damage Reduction with ECC
After ~2% drift
Reinforced Concrete Hinge Region
ECC Hinge Region
Precast Segmental Bridge Piers with Unbonded Post-tensioning for self-centering
18”
12 ft.
After ~4% drift
ρv=2% ρv=2%
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Example #2: Damage & Spalling Resistance of Bridge
Columns with self-compacting HyFRC (SC-HyFRC)
PEER funded project (Ostertag& Panagiotou)
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SC-HyFRC TEST SPECIMENS
12" Clear Cover to Spiral
W3.5 ContinuousSpiral @ 2.5"
Cross Section A-A
16"8 # 5
• 1:4.7 Scale Specimens • Aspect Ratio, H / D = 4
• Axial Load Ratio, N / f’c Ag = 0.1
Rubber Mastic Tape
A
2612"
66"
6714"
Point of LoadApplication
A
2"16"
7314"
(ρv = 0.37%)
(ρl = 1.2%)
66"
18"
6714"
Point of LoadApplication
A
2612"
A
Ø 18" Continous Corrugated DuctThickness = 0.064"
7314"
Designed to rock at column/foundation interface
Designed for plastic hinge formation
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SPALLING & DAMAGE Resistance in SC-HyFRC Bridge Columns compared to
conventional concrete columns
• Damage resistance of SC-HyFRC Columns, compared to conventional Concrete Columns after being subjected to approx. same drift ratio of 4%
• In SC-HyFRC columns spalling of cover occurs only locally and is delayed up to 3.6% drift ratio despite half the transverse reinforcement ratio, (ρv), 0.37% vs. 0.7%).
TS-1(a), TS-2 (c); Conv. Concrete ρv= 0.37%; ρv= 0.7%
Ostertag and Panagiotou (PEER 2011/106) Terzic et al, (2009)
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Self-compacted HyFRC column
ρv=0.37%
Conv. reinforced concrete column
ρv=0.70%
Self-compacted HyFRC column during 11% drift
-3 -2 -1 0 1 2 3 -30
-15
0
15
30
Lateral Displacement, (in.)
4 2 0 2 4
(d)
Test Specimen 2Terzic - Base45y - direction
Damage and Spalling Resistance due to SC-HyFRC
PEER (Ostertag & Panagiotou)
Drift ratio: 3.6% 4.0%
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Example #3: Damage Resistance of bridge
approach slabs in area III due to HyFRC
Mitigate deterioration caused by:
early age cracking, environmental, &
mechanical loading conditions.
Mechanically induced
Truck loading Soil Consolidation
Fatigue Environmentally induced
Corrosion Frost Action
Alkali Silica Reaction
Early Age Cracking Shrinkage
Subsidence
CalTrans project (Ostertag)
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Multi-scale crack control in HyFRC on Flexural Performance of ½ scale bridge approach slabs
HyFRC versus reinforced concrete ½ scale bridge approach slab
Blunt & Ostertag, ACI, Vol. 106, p. 265 (2009) Blunt & Ostertag, ASCE, Vol. 135, p. 978 (2009) CalTrans Report No. CA09-0632, 2008.
Beam size: 6”x6”x24” (15cm x15cm x60cm) Fibers: PVA microfibers and steel macrofibers
(Vf=1.5%) 6in
#3
#4
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Damage Resistance of Reinforced HyFRC
Macrocrack formation after 5 cycles of 9.5 kip loading
No crack formation after 5 cycles at 9.5 kips
Flexural Performance of ½ scale bridge approach
slabs
Ostertag and Blunt, FraMCoS-7 Jeju Korea, 2010 Blunt and Ostertag, ACI J. Engrg. Mech., 2009
Reinforced Concrete Reinforced HyFRC
0
10
20
30
0 0.05 0.1 0.15Midpoint Displacement [in.]
Ap
plie
d L
oad
[ki
ps]
HyFRC
Control
Reinforced concretee
Reinforced HyFRC 6in
#3
#4
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Damage Resistance of Reinforced HyFRC at despite 2x the applied load
Macro crack formed in control concrete after 5 cycles of 9.5 kip
loading
Only Microcracks formed in HyFRC after 5 cycles despite
double the load level
Flexural Performance of ½ scale bridge approach
slabs
Ostertag and Blunt, FraMCoS-7 Jeju Korea, 2010 Blunt and Ostertag, J. Engrg. Mech., 2009
Reinforced Concrete Reinforced HyFRC
0
10
20
30
0 0.05 0.1 0.15Midpoint Displacement [in.]
Ap
plie
d L
oad
[ki
ps]
HyFRC
Control6in
#3
#4
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Exposure of pre-loaded Control and HyFRC beams to 3% NaCl ponding solution
Tensile Surface (in flexure) exposed to 3% NaCl
ponding solution in hot chamber (50°C at 50% RH)
Electrochemical measurements: Corrosion potential measurements Polarization resistance measurements Galvanic current flow measurements
HyFRC
Control
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Effect of HyFRC on Frost Resistance
HyFRC: after 220 cycles
Plain Concrete: after 50 cycles
ASTM C666 test
Cycling temperature: +4°C to –18°C
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HPFRCCs enhance damage resistance and durability plus:
Provide Internal confinement and tension-stiffening [see student Poster (PEER funded project Billington & Ostertag on ECC and HyFRC]
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Unconfined SC-HyFRC and Control (SCC) in compression
SC-HyFRC provides internal confinement which i) Leads to stable softening behavior
ii) Provides spalling and damage resistance & iii) Allows reduction in transverse reinforcements
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Internal Confinement of HyFRC leads to spalling and damage resistance
ρs = 0.5%
SC-HyFRC: delay in damage initiation and damage progression
Concrete: extensive spalling
Cylinders: 6”x12”
Confined specimens tested in compression
0
10
20
30
40
50
0 2.5 5 7.5 10 12.5 15
Ave
rage
Str
ess
(MPa
)
Axial Displacement (mm)
Plain Concrete SC-HyFRC
Peak Load 7.5 mm 12.5 mm
PEER project Billington & Ostertag
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Large-Scale Verification Better performance in SC-HyFRC with half the spiral reinforcement
Drift Ratio 3.6%
Conv. reinforced concrete column, ρs = 0.70%
Self-compacted HyFRC column during 11% drift
-3 -2 -1 0 1 2 3 -30
-15
0
15
30
Lateral Displacement, (in.)
4 2 0 2 4
(d)
Test Specimen 2Terzic - Base45y - direction
PEER (Ostertag & Panagiotou)
Self-compacted HyFRC column ρs = 0.37%
4.0%
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HPFRCCs enhance damage resistance and durability plus:
Provide Internal confinement and tension-stiffening (see Poster by Billington & Ostertag on ECC and HyFRC) Provide Shear resistance (Prof. Billington in TSRP session on High Performance materials and Sustainable Structural Design)
Provide Impact Resistance (Dr. Vossoughi in TSRP session on High Performance materials and Sustainable Structural Design)
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Multi-scale Crack Control in HyFRC on Impact Resistance
Panel size: 12”x12”x1”
Back Face
Velocity of projectile: 167m/s
HyFRC
Velocity of projectile: 127m/s
Plain Concrete
Back Face
Vossoughi et al
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Reservations towards HPFRCCs
“…HPFRCs in structures will lead to
higher initial cost…” True…… but:
HPFRCCs allow new design possibilities due to enhanced performance and allow reduction in steel reinforcement Less Repair and extended Service Life
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Reservations towards HPFRCCs
“…HPFRCs in structures will lead to
higher initial cost…” True…… but:
HPFRCCs allow new design possibilities due to enhanced performance and allow reduction in steel reinforcement Less Repair and extended Service Life
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BAS Detail Modification due to HyFRC
#8 @ 6 in. (ρs = 1.1%)
#6 @ 12 in. (ρs = 0.3%)
Type R(9S) Metric Designation
CalTrans project
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HPFRC allow new design possibilities due to enhanced performance
HyFRC ECC
HyFRC
Current PEER Project on precast structural HyFRC
tubes as permanent formwork
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Reservations towards HPFRCCs
“…HPFRCs in structures will lead to
higher initial cost…” True…… but:
HPFRCCs allow new design possibilities due to enhanced performance HPFRC allow reduction in steel reinforcement Less Repair and extended Service Life
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Higher initial cost but less repair and Extended Service Life
HPFRCCs have the potential to extend the initiation phase and slow down the propagation phase of damage
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HPFRCCs extend the Damage Initiation Phase
Because HPFRCCs provide the necessary crack resistance and thereby minimize ingress of aggressive agents into the concrete
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Extending Damage Initiation Phase due to HyFRC
Dominant crack in control specimens after 5 cycles
Control BAS HyFRC BAS
No cracks in HyFRC after 5 cycles (same load)
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Slowing down Damage Propagation Phase with HyFRC
Microfibers bridge these microcracks in close vicinity to the reaction site at onset
microfibers
reactive aggregate
microcracks
corrosion product
reinforcing steel
ASR
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Reservations towards HPFRCCs
“… for Corrosion resistance why not using stainless steel rebars...”
Yes…. but not effective in regards to other environmental deterioration processes such as ASR, damage due to frost action, sulfate attack etc…
ASR damage
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Concerns in regards to HPFRCCs
“…Adding fibers reduces workability … makes it more difficult for CIP applications specially for structures in seismic prone regions that are heavily reinforced... ”
In principle true … but not anymore … due to self-compacting HPFRCs
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SC-HyFRC FOR BRIDGE COLUMNS
Casting of Self-compacting HyFRC bridge columns without external and internal vibration
(PEER funded project; Ostertag & Panagiotou).
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Concerns in regards to HPFRCCs
“HPFRCC matrix grabs onto rebar and cause localization and premature failure of rebar” True for UHPFRC … but not for ECC and HyFRC (see PEER student poster on confinement and tension stiffening; PEER project: Billington & Ostertag)
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Tension stiffening and high ultimate load capacity of ECC, HyFRC and SC-HyFRC
ECC, HyFRC and SC-HyFRC are able to carry tension to strains far
greater than the yield strain of the steel reinforcing bar
PEER Poster session: “Tension stiffening and Confinement in HPFRCCs”: Billington & Ostertag;
Poster presenter: Will Trono (UCB) 41” long with 5”x 5”
cross-section ρ=1.2%
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Summary
HPFRCCs Enhance Damage Resistance (when exposed to both seismic and environmental loading conditions) Extend Service Life of concrete structures Make Structures more sustainable (by preserving our resources)
TS-1(a), TS-2 (c); Conv. Concrete ρv= 0.37%; ρv= 0.7%
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Summary
HPFRCCs
Provides a Holistic Approach towards enhancing the Durability of concrete structures
(i.e. it does not only mitigate corrosion but also ASR, frost damage, salt scaling, drying shrinkage… etc).
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Research NEEDS:
Whereas mechanical properties of plain HPFRCCs have been studied and are well documented, Few studies exist on synergy between HPFRCC matrix and steel rebar. Model development and establish design guidelines Need large scale test verification for HPFRCCs in CIP and ABC applications
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TSRP session on High Peformance Materials & Sustainable Structural Design; Session Chair: Prof. Billington (Sa afternoon)
Speakers Affiliation Title of presentation
Phil Hoffman Structural Design and Usage of Micro-Reinforced Concrete (Ducon) for Seismic jacketing and other Applications
Ying Zhou Tongji University, Shanghai, China High Performance Concrete Structural Walls for Tall Buildings
Fariborz Vossoughi
Ben C. Gerwick, Inc. Impact Resistance of High Performance Materials
Sarah Billington
Stanford University
Performance and Modeling of Damage Tolerant Fiber-reinforced Concrete in Seismic Retrofits
Claudia Ostertag UC Berkeley
Durable and Damage Resistant High Performance Fiber reinforced Bridge Structures
Lindsey Maclise
Forell/Elsesser Engineers, Inc Sustainable Materials Certification
Arpad Horvath UC Berkeley Principles of Sustainable Design for Structures
Michael Lepech
Stanford University
Life Cycle Assessment of Concrete Structures in Multi-hazard Environments
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Thank you for your attention
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Corrosion Experiments revealed that splitting bond cracks in reinforced concrete increase Cl ingress
Fine cracks parallel to rebar (splitting bond cracks) in control specimens
Splitting bond cracks not observed in HyFRC due to : 1)Fibers reduce load demand on rebar thereby reducing bond stresses
2)Fibers effective in reducing crack propagation and growth of bond cracks