LEGACY REPORT

ICC Evaluation Service, Inc.

ER-5558
Reissued February 1, 2004

www.icc-es.org

Business/Regional Office # 5360 Workman Mill Road, Whittier, California 90601 # (562) 699-0543 Regional Office # 900 Montclair Road, Suite A, Birmingham, Alabama 35213 # (205) 599-9800 Regional Office # 4051 West Flossmoor Road, Country Club Hills, Illinois 60478 # (708) 799-2305

Legacy report on the 1997 Uniform Building Code

DIVISION: 03CONCRETE Section: 03930Concrete Rehabilitation CONCRETE AND MASONRY STRENGTHENING USING THE HEX-3R STRUCTURAL COMPOSITE SYSTEM HEXCEL REINFORCEMENTS CORPORATION 2200 SOUTH MURRAY AVENUE ANDERSON, SOUTH CAROLINA 29624 BONDO CORP. 3700 INDUSTRIAL PARKWAY NW ATLANTA, GEORGIA 30331 SIKA CORP. 201 POLITO AVENUE LYNDHURST, NEW JERSEY 07071 1.0 SUBJECT Concrete and Masonry Strengthening Using the HEX-3R Structural Composite System. 2.0 DESCRIPTION 2.1 General: The HEX-3R Structural Composite System is used as an alternate to systems addressed in the 1997 Uniform Building Code (UBC), to strengthen concrete and masonry structural elements. Table 1 summarizes all product names used by Hexcel Reinforcements Corporation and the additional listees. 2.2 Materials: 2.2.1 HexWrap High-strength Fabric: The HexWrap highstrength fabric is composed of either carbon, aramid or glass fibers. HexWrap 100 is a glass-fiber, unidirectional fabric weighing 27 ounces per square yard (917 g/m2). HexWrap 103 is a carbon-fiber, unidirectional fabric weighing 18 ounces per square yard (611 g/m2). HexWrap 106 is a glassfiber, open-weave fabric weighing 8.7 ounces per square yard (295 g/m2). HexWrap 107 is similar to HexWrap 100 and is additionally composed with aramid fibers in the weft direction. HexWrap 230 is a carbon-fiber, unidirectional fabric weighing 6.7 ounces per square yard (228 g/m2). Standard rolls of fabric are shipped in 12-inch-by-13-inch-by-64-inch (305 mm by 330 mm by 1626 mm) boxes, and special roll sizes are available. Material properties vary with fiber type. 2.2.2 Hex-3R 300, 306 and 306XR Epoxy: The matrix is an ambient-cure epoxy mix used to bind and environmentally protect the fibers. Components A and B of the matrix are shipped in either 5-gallon (18.9 L) buckets or 50-gallon (189.3 L) drums and are mixed at either the jobsite or the factory, prior to application. 2.2.3 Hex-3R Composites: Hex-3R composites are comprised of materials covered in Sections 2.2.1 and 2.2.2 of this report. 2.2.3.1 Wrap 107 Composite: In the primary direction, the glass-fiber composite has a design ultimate tensile strength of 86.6 ksi (597 MPa), design tensile modulus of 3.58 103 ksi (24.6 103 MPa), and design elongation of 2.33 percent. Layer thickness is 0.040 inch (1 mm). 2.2.3.2 Wrap 100 Composite: In the primary direction, the glass-fiber composite has a design ultimate tensile strength of 81 ksi (558 MPa), design tensile modulus of 3.55 103 ksi (24.4 103 MPa), and design elongation of 2.23 percent. Layer thickness is 0.040 inch (1 mm). 2.2.3.3 Wrap 103 Composite: In the primary direction, the carbon-fiber composite has a design ultimate tensile strength of 104 ksi (716 MPa), design tensile modulus of 9.93 103 ksi (68.4 103 MPa), and design elongation of 0.98 percent. Layer thickness is 0.040 inch (1 mm). 2.2.3.4 Wrap 230 Composite: In the primary direction, the carbon-fiber composite has a design ultimate tensile strength of 119 ksi (820 MPa), design tensile modulus of 10.25 103 ksi (70.6 103 MPa), and design elongation of 1.16 percent. Layer thickness is 0.013 inch (0.33 mm). 2.2.3.5 Wrap 106 Composite: In the primary direction, the glass-fiber composite has a design ultimate tensile strength of 35.3 ksi (243 MPa), design tensile modulus of 2.35 msi (16.2 GPa), and design elongation of 1.43 percent. Layer thickness is 0.013 inch (0.33 mm). 2.2.4 Hex-3R FireLam 505: The Hex-3R base coat is a twocomponent epoxy material. Component A is packaged in 2.4gallon (9 L) containers. Component B is packaged in 0.59gallon (2.23 L) containers. 2.2.5 Hex-3R FireLam 506: The Hex-3R top coat is an acrylic paint packaged in 3-gallon (11.36 L) containers. 2.2.6 Storage Recommendations: For the epoxies, finishes and fibers should not be subjected to water contamination or exposed to temperatures above 100/F (38/C). Storage life shall not exceed one year for the Hex-3R FireLam 506, two years for the epoxies, and ten years for the fibers. 2.3 Material Properties: All materials shall comply with specifications outlined in the Hexcel Reinforcements Corporation quality control manual (hereafter referred to as the QCM), dated December 6, 1999.

ICC-ES legacy reports are not to be construed as representing aesthetics or any other attributes not specifically addressed, nor are they to be construed as an endorsement of the subject of the report or a recommendation for its use. There is no warranty by ICC Evaluation Service, Inc., express or implied, as to any finding or other matter in this report, or as to any product covered by the report.

Copyright 2004

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Page 2 of 3 2.3.1 Bond Strength: The bond strength of the system to a properly prepared surface shall exceed the tensile strength of the substrate. Testing in accordance with ASTM D 4541 can be used to estimate the bond strength of installations. Sufficient bond area shall be used to prevent bond failure. 2.4 Installation:

ER-5558 2.5.5.2 Structural Design Requirements: Concrete design shall comply with the Engineering Guidelines and with Sections 1907, 1909, 1910, 1911, 1912, and 1921 of the UBC. Masonry design shall comply with the Engineering Guidelines and with Section 2108 of the UBC. 2.5.6 Beams and Slabs: 2.5.6.1 Potential Applications: Beams can be strengthened to enhance their ductility and their flexural and shear strengths. Slabs can be strengthened to enhance flexural and in-plane shear strengths. 2.5.6.2 Structural Design Requirements: Concrete design shall comply with the Engineering Guidelines and with Sections 1907, 1909, 1910, 1911, 1912 and 1921 of the UBC. Masonry design shall comply with the Engineering Guidelines and with Section 2108 of the UBC. 2.5.7 Walls and Wall-Slab Connections: 2.5.7.1 Potential Applications: Walls can be strengthened to enhance out-of-plane flexural, in-plane flexural and shear strengths. 2.5.7.2 Structural Design Requirements: Concrete wall design shall comply with the DM and with Sections 1907, 1909, 1910, 1911, 1912, 1914 and 1921 of the code. Masonry wall design shall comply with the Engineering Guidelines and with Sections 2106 and 2108 of the UBC. 2.6 Special Inspection:

Installation shall be performed by applicators certified by Hexcel Reinforcements Corporation. Installation of the system is detailed in Section 3.2 of the Engineering Guidelines published by Hexcel Reinforcements, dated August 1999. 2.4.1 Saturation: The fibers and the matrix are combined in accordance with an established weight and volume ratio, using the calibrated Hex 3-R Saturator or manual methods. 2.4.2 Application: The composite fabric is applied to the substrate using manual methods. Manual methods are used to remove air bubbles and to ensure desired fiber orientation. Pot life of the saturated fabric is 3 hours at 70/F (21/C), and varies with temperature. Higher temperatures result in a shorter pot life, and lower temperatures result in a longer pot life. 2.4.3 Finishing: A final layer of thickened epoxy is applied and can be coated with one of the following: 2.4.3.1 Paint: Paints are applied as environmental and aesthetic considerations. required for

2.4.3.2 Flame-spread Coating: When applied to structural elements to satisfy code requirements for interior finish, the Hex-3R FireLam 505 and Hex-3R FireLam 506 yield a Class I flame-spread rating and a smoke-density requirement in accordance with Section 802.2 of the UBC. The composite is limited to a maximum of six layers. Application instructions for the Hex-3R FireLam 505 and the Hex-3R FireLam 506 are found in Section 3.2 of the Engineering Guidelines. 2.4.4 Cure Time Prior to Loading: The Hex-3R composites shall be allowed 48 hours of cure time prior to the loading of the structural member. 2.5 Design:

Special inspection during the installation of the system shall be in accordance with Section 1701 of the UBC. Special inspection during installation of the system shall also be in accordance with the ICC-ES Interim Criteria for Inspection and Verification of Concrete and Reinforced and Unreinforced Masonry Strengthening Using Fiber-reinforced Polymer (FRP) Composite Systems (AC178), dated June 2003. 2.7 Identification:

2.5.1 General: Design of the composite system is based on ultimate strength design requirements in accordance with Chapters 19 and 21 of the UBC. The owner and structural design professional are responsible for determining, through analysis, the design strengths and demands of the structural elements to be enhanced by the Hex-3R System. 2.5.2 Composite Design Properties: Structural design properties for the composites are found in Section 9 of the Engineering Guidelines. 2.5.3 Design Details: Design equations are based on test results and principles of structural analysis. Basis of design includes strain compatibility and limit states. All designs follow procedures as detailed in the code; in the ICC-ES Interim Criteria for Concrete and Reinforced and Unreinforced Masonry Strengthening Using Fiber-reinforced, Composite Systems (AC125), dated June 2003; and in the Engineering Guidelines. The engineering guidelines also provide guidance on protecting the composite materials in areas where they are prone to impact. 2.5.4 Factors of Safety: The strength reduction factors and load factors used shall comply with the UBC. 2.5.5 Columns: 2.5.5.1 Potential Applications: Columns can be strengthened to enhance their ductility and their axial, flexural and shear strengths, and to provide confinement of lap splices of steel reinforcement.

Products of the structural composite system are labeled, in accordance with the QCM, with the manufacturers name and address, product name, expiration date, evaluation report number (ER-5558) and name of the quality control agency (Underwriters Laboratories Inc.). 3.0 EVIDENCE SUBMITTED Data in accordance with the ICC-ES Interim Criteria for Concrete and Reinforced and Unreinforced Masonry Strengthening Using Fiber-reinforced, Composite Systems (AC125), dated June 2003; and quality control manuals. 4.0 FINDINGS That Concrete and Masonry Strengthening Using the HEX-3R Structural Composite System described in this report complies with the 1997 Uniform Building Code (UBC), subject to the following conditions: 4.1 4.2 Design and installation are in accordance with this report, the manufacturers instructions and the UBC. Copies of the Hexcel Reinforcements Corporation Quality Control Manual, dated December 6, 1999, and Engineering Guidelines, dated August 1999, are submitted to the building official for approval with each project using the system. Fire-resistance of the assembly must comply with Chapter 7 of the UBC and is not reduced by application of the HEX-3R system. Fire-resistance of assemblies with structural load-carrying capacities increased beyond code levels by the HEX-3R system is beyond the scope of this report. Fire protection

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Page 3 of 3 for the composite systems shall be subject to building official approval. 4.4 4.5 Special inspection is provided in accordance with Section 2.6 of this report. To satisfy Item 2, Section 215, of the UBC, regarding noncombustible construction, the flame-spread coating described in Section 2.4.3.2 of this report is limited to 1/8-inch (3.2 mm) thickness, maximum. Concrete members are fabricated by an approved fabricator complying with Section 1701.7 of the UBC, or are fabricated with continuous special inspections in accordance with Sections 1701.5.1 and 1701.5.3 of the UBC. 4.7

ER-5558 Masonry members are fabricated with continuous special inspections in accordance with Section 1701.5.7 of the UBC. HEX-3R materials are manufactured at 1850 South Sequin Avenue, New Braunfels, Texas; 1913 North King Street, Seguin, Texas; and 8250 Commercial Street, La Mesa, California, with quality control inspections by Underwriters Laboratories Inc. (AA668).

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4.6

This report is subject to re-examination in two years.

TABLE 1CROSS-REFERENCE OF PRODUCT NAMES HEXCEL REINFORCEMENTS NAME HexWrap Hex-3R 300 HexWrap Hex-3R 306 HexWrap H-3R 306XR HexWrap Hex-3R Wrap 107 HexWrap Hex-3R Wrap 100 HexWrap Hex-3R Wrap 103 HexWrap Hex-3R Wrap 230 HexWrap Hex-3R Wrap 106 HexWrap Hex-3R FireLam 505 HexWrap Hex-3R FireLam 506
1

BONDO NAME Pro Force Structural Epoxy1 Pro Force Structural Epoxy 23100 Pro Force Structural Epoxy 23500

SIKA NAME Sikadur Hex 300 Sikadur Hex 360 Sika Wrap Hex 107G Sika Wrap Hex 100G Sika Wrap Hex 103C Sika Wrap Hex 230C Sika Wrap Hex 106G

Pro Force Structural Epoxy consists of HexWrap HEX-3R306 combined in a kit with HexWrap Hex-3R Wrap 100 or HexWrap Hex-3R Wrap 230.