Design of FRP-Profiles and All-FRP-Structures

Design of FRP-Profiles and All-FRPStructures Structures
- Lecture: Dr. Ann Schumacher, ann.schumacher@empa.ch - Exercise: Dr. Andrin Herwig, andrin.herwig@empa.ch
References: Bank, L. Composites for Construction - Structural Design with FRP Materials, John Wiley & Sons, Inc., 2006. (Chapters 12 - 15) Fiberline. Fiberline Design Manual, www.fiberline.dk, 2003. Clarke, JL. (Ed.) Structural Design of Polymer Composites - EUROCOMP Design Code and Handbook, E & FN Spon, 1996.
Design of FRP-Profiles and All-FRP-Structures
Fibre Composites, FS09
A. Schumacher / 14.10.2009
Outline
Introduction
(Pros and cons of FRP / Examples)
Materials
(Manufacturing process / Materials / Durability)
Design Concept
(Concept / Basic assumptions / )
Bending Beam
(Timoshenko theory / Stresses / Deformations / Buckling )
Axial Members
(Serviceability and ultimate limit states)
Connections
(Bolted joints / Glued joints)
Design of FRP-Profiles and All-FRP-Structures Fibre Composites, FS09 A. Schumacher / 14.10.2009
Introduction
Introduction: Pros and cons
Pros
High specific strength:
Material
lmax =
CFRP 138.4 km
GFRP 27.8 km
Steel S500 6.4 km
max g
Good in-plane mechanical properties High fatigue and environmental resistance Adjustable mechanical properties Lightweight Quick assembly / erection Low maintenance Highly cost-effective (2-10 /kg)
Introduction: Pros and cons
Cons
Lightweight Brittle High initial costs Low to moderate application temperature (-20 up to 80 C) Low fire resistance (sometimes with unhealthy gases)
Introduction: Common profiles
Structural profiles
Most structural profiles produced in conventional profile shapes similar to
metallic materials
Similarity in geom. and properties, however no standard geom.,

mechanical and physical properties used by all manufacturers
Structural profiles
Non-structural profiles
Introduction: Examples
Footbridges
Pontresina bridge, Switzerland Span: 2 x 12.5 m Weight: 3.3 tons (installation by helicopter)
http://www.fiberline.com/gb/casestories/case1830.asp
Fiberline Bridge in Kolding, DK Span: 40 m Cost: 0.5 mio CHF Only Fiberline standard profiles used
Footbridges
Composite pedestrian bridge in Lleida, Spain Span: 38 m Width: 3.0 m

Introduction: Examples (ASSET Profile)
Road bridges
West Mill Bridge, England Span: 10 m Width: 6.8 m Load capacity: 46 tons
Klipphausen Bridge, Germany Span: 6.8 m Width: 6.0 m Load capacity: 40 tons
Bridgedeck (Footbridges)
Wrenlos, Switzerland Loopersteg, Switzerland
Buildings
Eyecatcher Building, Basel, Switzerland Height: 15 m Storeys: 5

Project: Maagtechnic
Laboratory bridge
Empa Laboratory Bridge, Switzerland Span: 19 m Width: 1.6 m Load capacity: 15 tons
Noise barrier SBB
Gschenen, Switzerland Project: Maagtechnic
Balconies
Switzerland Project: Maagtechnic

Railings
Oensingen, Switzerland
Heineken brewery, Switzerland
Introduction: Application
Applications where GFRP structures are competitive:

Significant corrosion and chemical resistance is required
(Food and chemical processing plants, cooling towers, offshore platforms )
Electromagnetic transparency or electrical insulation is required. Light-weight is cost essential

(fast deployment )
Prestige and demonstration objects

(e.g. Novartis Campus Entrance Building)
Photo: Prof. Th. Keller, EPFL
Material
Material: Pultrusion process
Only pultruded GFRP profiles will be considered in this lecture
Pultrusion line
Production of profiles with constant cross-section along the length High quality Continuous longitudinal fiber bundles and filament mats
Material: Components
Pultruded profiles contain three primary components:

reinforcement Matrix
polyester epoxy phenol
Supplementary
constituents
polymerisation agents fillers additives
Material: Shapes of pultruded profiles Available Profiles on Stock:
Length up to 12 m!
Special cross-sections can be designed and ordered

(several kilometres are necessary special tools have to be designed)
Material: Durability Various environmental and load conditions that affect durability of
(G)FRPs in terms of strength, stiffness, fiber/matrix interface integrity, cracking:
water/sea water chemical solutions prolonged freezing thermal cycling (freeze-thaw) elevated temperature exposure UV radiation creep and relaxation fatigue fire
Material: Durability Environmental reduction factor for different FRP systems and
exposure conditions
Exposure condition Interior exposure Fiber / resin type Carbon/epoxy Glass/epoxy Aramid/epoxy Exterior exposure
(bridges, piers parking garages)
Environ. reduction 0.95 0.75 0.85 0.85 0.65 0.75 0.85 0.50 0.70
Carbon/epoxy Glass/epoxy Aramid/epoxy Carbon/epoxy Glass/epoxy Aramid/epoxy
Agressive environ.
(chemical plants)
Material: Durability GFRP is more susceptible to degradation than CFRP by the

following effects:
alkaline effects (caution when GFRP in contact with concrete!) acid effects salt effects fatigue UV radiation
Fire protection is a major (unsolved) issue for (G)FRP structural

elements and components
Smoke generation and toxicity must be considered
Strength of GFRP is affected by fatigue loading

(more than CFRP)
Material: Manufacturers
GFRP profiles available on stock

In Europe two companies pultrude FRP-Profiles:
Fiberline Composites, Denmark

www.fiberline.com Fiberline Design Manual (www.fiberline.dk) helpful tool to design structures (material properties, geometries, connections, )
Top Glass, Italy

www.topglass.it
Material: Manufacturers
GFRP profiles available on stock

In North America:
Strongwell, USA
www.strongwell.com
Creative Pultrusions, USA

www.creativepultrusions.com
Bedford Reinforced Plastics, USA

www.bedfordplastics.com
Design Concept
Design Concept: Basic Assumptions Definitions and directions
Design Concept
Codes
Every manufacturer has its own profile design No European Design
Code is available! (only EN13706, about testing and notation)
There exists European guidelines: EUROCOMP 1996 Design Code

EUROCOMP 1996 Handbook
Fiberline Design Manual is based on Eurocomp 1996.

Design concept (according to Eurocodes and Swisscodes) Partial safety factors Measured material parameters Rules for bolted connections
Design Concept
Concept of Limit State Design (According to Euro Codes and Swiss Codes) Ultimate limit stress
Ed Rd
Ed Rd Calculated stress (including load factors) SIA260 / 261 Rated value of the resistance capability where
Rd =
Rk
m
Rk the calculated resistance capability
Design Concept Reduction coefficient

Coefficient Description Derivation of mat. properties Degree of postcuring Production process Operating temperature
Operating temperature C -20 ... +60 80
m = m,1 m,2 m,3 m,4

Max.
Min.
m
1.1 1.0
Fiberline 1.15 1.1 1.0
m,1 m,2 m,3 m,4
2.25 1.6 2.0
1.15
m,4
Short-term load 1.0 1.25 Long-term load 2.5 3.13
Design Concept
Serviceability limit states

Ed Cd
Ed the crucial action effect due to the load cases considered in the investigated dimensioning situation. Typically maximal deflection response of the structure. corresponding serviceability limit. SIA 261
Cd
Design Concept: Basic Assumptions Material Properties, stength values (Fiberline Profiles)
Design Concept: Basic Assumptions Material Properties, stiffness values (Fiberline Profiles)
Design Concept: Basic Assumptions Typical data sheet of a profile (Fiberline I-Profile)
Bending Beam
Bending Beam: Design of Calculate bending moments Md and shear forces Qd acting on the profile,
using the partial coefficient (SIA 260 / 261)
Ultimate limit state

Bending:
Md,y,max f b,0 Md, z,max + max = m Wy W z
Shear:
Qd,y,max f max = Ak,y m

Ak relevant shear area
Bending Beam: Design of Serviceability limit state

Deflection limit: wmax < 1 L
typically selected between 200 and 400 given by SIA 261 or the building owner
wmax calculated including shear deformations
Vibrations
Light-weighted and soft structures are susceptible to vibrations (traffic, wind, the movement of people )!!
Bending Beam: Timoshenko Theory Pultruded profiles have a low shear modulus shear deformation
must be taken into account!
Several bending theories have been published for beams:

Euler-Bernoulli theory (1702) Timoshenko theory (1968) Higher order beam theory
A simply supported beam with a symmetric cross-section is discussed
Bending Beam: Timoshenko Theory
Cross-sections plane and perpendicular 1 degree of freedom w
Cross-sections plane but NOT perpendicular 2 degrees of freedom w and
Cross-sections do NOT remain plane 3+ degrees of freedom w, and
Bending Beam: Euler vs. Timoshenko Theory

Kinematic relationships
ux = y w( x),x u y = w( x)
ux = y ( x) u y = w( x)
x = ux = y w( x),xx
x u y u x + =0 2 xy = y x
x = ux = y ( x),x
x u y u x + = ( x) + w( x),x 2 xy = y x
Hooks law
x = E0 x and xy = G 2 xy
M z = y x dydz = w,xx E0 Iz
QS
M z = y x dydz = ,x E0Iz Qy = dydz = ( w,x ) GA

QS
Fibre Composites, FS09 A. Schumacher / 14.10.2009
QS

Equilibrium
In a first approximation, the deflections are calculated by direct integration of: Equilibrium on an infinitesimal beam element:
w,xx = M ( x) E0 Iz
q( x) = Q,x = ( w,xx ,x ) GA
M ,x Q = ,xx E0Iz + ( w,x ) GA = 0

Coupled second order differential equation
Solution for the simply supported beam (distributed load)

M ( x) =
w, xx =
1 1 qLx qx 2 , w(0) = 0 and w( L) = 0 2 2
w(0) = 0 and w( L) = 0 M (0) = 0 , x (0) = 0 and M ( L) = 0 , x ( L) = 0
1 1 1 2 qLx qx E 0 I z 2 2
Functions:
w( x) = A1 x 4 + A2 x 3 + A3 x 2 + A4 x + A5
w( x) =
qx ( L3 2 Lx 2 + x 3 ) 24 E 0 I z
( x) = B1 x3 + B2 x 2 + B3 x + B4

Put in , E I + ( w, ) GA = 0 and solve for the coefficients
xx 0 z x
B1 = 4 A1 , B3 = 2 A3 B2 = 3 A2
24 A1 E 0 I z GA 6A E I , B4 = 2 0 z A4 GA
Use the boundary conditions and the second differential eq. to calculate A1 A5:
2 2 qx ( L x ) qx ( L x ) ( L + Lx x ) w( x) = + 2 GA 24 E 0 I z
Deflection at midspan
5 qL4 L w = 2 384 E I z 0
5 qL4 + q L2 L w = 2 384 E I z 8 GA 0

General expression for the total beam deflection as a sum of the deflection
due to bending and shear:
f1 ( x) f 2 ( x) w( x) = + E0 I z GA
f1 ( wmax )
5 qL4 384 PL3 48 qL4 8 PL3 3
Beam Simply supported Uniformly distr. load (q) Concentrated load (P) Cantilever beam Uniformly distr. load (q) Concentrated load (P)
f1 ( wmax )
qL2 8 PL 4
x( wmax )
L 2 L 2
qL2 2
L L
PL
Bending Beam: Euler vs. Timoshenko Theory Example: influence of the shear deformation
Profile: 300 x 150 mm I-beam Load: uniformly distributed
General rule of thumb: for GFRP beams with span/depth > 25, shear deformation can be ignored
Bending Beam: Example
Choose an appropriate Profile for the following specifications

L qd,uls qd,ser wmax/L = = = = 3.0 m 13 kN/m 10 kN/m 1/300 wmax=0.01 m
1. Deflections and loading

5 qd ,ser L4 qd ,ser L2 + wmax = 384 E0I z 8 GA
qd ,uls L2 h max = 8 2 Iz
qd ,uls L 1 max = 2 Ak,y
Bending Beam: Example 2. Find a profile with sufficient bending stiffness.

Shear deformations are neglected in a first step:
5 qd ,ser L4 = 1.054 106 Nm2 E0I z 384 wmax

from specification table: choose I 240x120x12 E I z =1.369 106 Nm2 0
3. Check the bending and shear stresses

qd ,uls L2 h max = = 35.8 MPa 8 2 Iz qd ,uls L 1 max = = 7.1 MPa 2 Ak,y
f b,0,d =185 MPa f ,d = 20 MPa
Bending Beam: Example 4. Check deflection (including shear deformation)

wmax = 5 qd , ser L4 384 E0 I z
(7.7 mm)
qd , ser L2 8 GA
(1.6 mm)
= 9.3 10 3 m
wmax = 0.01 m
wmax =
5 qd , ser L4 384 E0 I z
qd , ser L2 8 GAweb
= 9.110 3 m
5. Remarks:
The design of GFRP-profiles is mostly driven by serviceability criteria. Start the design iteration procedure using the maximal deflection criterion.
Bending Beam: Stability problems Lateral-torsional buckling

Flange (compressive) displace laterally to the
transverse load direction.
Torsional stiffness is too low (especially for

open section profiles)
Theoretical calculations or design measures.

see e.g. L.P. Kollr 2003, Mechanics of composite structures.
Example:
Compressive flanges are kept in place by connection to the bridge deck.

Bending Beam: Stability problems Local buckling of walls due to in-plane compression
Flange (compressive) displaces in the
direction of the transverse load.
Low bending stiffness perpendicular to the

pultrusion direction.
Weak fiber mats.
Local buckling of walls due to in-plane shear Web crushing and web buckling in transverse direction
Axial Members
Axial Members: Tension Ultimate limit state under axial tension Nd

Nd f t,0 A m
Serviceability limit state

x = N L
E0 A
Remark: The critical aspect of axial members in tension are neither the serviceability
nor the ultimate limit state. Critical is the load transfer to the GFRP profile!
Axial Members: Compression Ultimate limit state under axial compression Nd

Nd Fc 1+ Fc NEuler A f c,0
FC = m
maximal compressive load
2 E0 I NEuler = 2 m,E Lk
Euler load
Lk Buckling length for columns
m,E coefficient for Youngs modulus = 1.3

Axial Members: Compression The influence of shear deformation should be considered, but in the most
cases, the influence will be small (less than 5%).
Local buckling should be considered for short columns. For more information on the various buckling modes and effects
see L.P. Kollr 2003, Mechanics of composite structures
Global buckling
Local buckling
Connections
Connections: Introduction
Connections: Introduction
(from Eurocomp Design Code 1996)
Connections: Bolted joints Bolts = Stress concentration in the profile and the bolt. It is necessary to ensure that the bolts and the profile
can withstand this concentrated local stress compression.
It is necessary to ensure that the region surrounding

a group of bolts will not be torn out of the profile.
Basic failure modes

in bolted shear connections:
bolt shear failure

Connections: Bolted joints The design procedure is comparable to the one for steel connections, but
since there exist no standard GFRP material each manufacturer has its own design rules for bolted joints.
IMPORTANT REMARKS:
The direction of pultrusion and the direction of the force is RELEVANT!!!
(anisotropic material)
Use stainless or galvanised steel Do not cut threads in the composite material! Use screws with shafts
Connections: Bolted joints (Fiberline recommendations) Calculation of load bearing capacity of bolts
Shear in longitudinal direction (0) Shear in transverse direction (90) Tensile force
Minimum distances
Connections: Bolted joints (Fiberline recommendations) Joint capacity tables, available for shear and tension
Shear in longitudinal direction 0
Shear in transverse direction 90
PB,d = d t 150 MPa m (=1.3)

PB,d = d t 70 MPa m (=1.3)

Connections: Bolted joints (Fiberline recommendations) Bolted connection in shear: e.g. shear in longitudinal direction
mPBolt dt720 MPa
mPBolt dt240 MPa
mPBolt dt240 MPa
mPBolt dt150 MPa
mPBolt dt240 MPa
Connections: Bolted joints (Fiberline recommendations)

Bolted connections in tension Static conditions
Bolt: Tearing of bolt in threaded cross-section
Pd m
As f yk
Laminate: Shear fracture at rim of washer
t f Pd 2 d
m
Geometry and strength:

d As t 2d fyk f ... ... ... ... Diameter of the bolt Stress area of the bolt Thickness of laminate Diameter of washer Tensile strength of bolt Shear strength of laminate
Connections: Bonded joints

Using an adhesive agent for joining profiles can have advantages:
Easy to use / easy to make aesthetic joints Typically more rigid than bolted joints Glued joints subjected to dynamic loads are good
But be careful
Adhesive agents have properties that depend on time, temperature, humidity Failure in glued joints takes place suddenly (brittle behaviour) The load-bearing capacity is not proportional to the area which is glued
The design of bonded joints may be based on:

Analytical models for plate-to-plate connections (see Eurocomp 1996 Design Code) Design guidelines supplemented by testing Finite element analysis

A bonded joint has the following three primary failure modes:
adhesive failure cohesive failure of adhesive cohesive failure of adherend
The design of any bonded joint shall satisfy the following conditions:

allowable shear stress in the adhesive is not exceeded. allowable tensile (peel) stress in the adhesive is not exceeded. allowable through-thickness tensile stress of the adhesive is not exceeded. allowable in-plane shear stress of the adherend should not be exceeded.
The calculation of the stresses has to be done very carefully! Often

calculations are supplemented by testing.

Different types of bonded joint configurations
Research on bonded joints for structural

applications
Connections: Other joints

Brackets for assembly (Fiberline)
Custom pultruded connections
GFRP: Some final remarks

Perpendicular to the direction of pultrusion, the material is WEAK and SOFT!
avoid such loadings if possible
In order to use pultruded GFRP-profiles economically, the design must be done

in a clever way! e.g.: for bridges, the railings should be used as part of the load-bearing structure
GFRP structures are very light vibration problems may occur

Design of FRP-Profiles and All-FRP-Structures

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