1. DOT-Federal Highway Administration HISTORY - FRP Fiber Reinforced Materials n Straw in Clay (Brick, Roof, Walls) n Glass Fibers in Concrete n Glass Fibers in Polymer

2. DOT-Federal Highway Administration HISTORY - FRP POST WW-II APPLICATIONS n Boat Hulls n Radomes n Minesweeping Vessels n Bath Tubs n Covers HS, CR, LW - New Developments in Filament Winding and Pultrusion

3. DOT-Federal Highway Administration HISTORY - FRP POST WW-II APPLICATIONS-2 n Pressure Vessels n Submarine Parts n Rocket Shells n Aircraft Components n Automobile Bodies & Parts

4. DOT-Federal Highway Administration HISTORY - FRP POST WW-II DOMESTIC APPLICATIONS n Bath Tubs n Covers n Railings n Housing Components n Architectural Components n Ladders n Electrical Equipment

5. DOT-Federal Highway Administration HISTORY - FRP POST WW-II RECREATIONAL USES n Fishing Rods n Tennis Rackets n Ski Equipment n Golf Clubs n Recreation Boats n Skates

6. DOT-Federal Highway Administration FRP CONSUMPTION (IN MILLION POUNDS) Source: SPI CI, April 99

7. DOT-Federal Highway Administration FRP - CIVIL STRUCTURES CURRENT FIELD ACTIVITIES n Pedestrian Bridges n Highway Bridges n Seismic Retrofit Columns n Bridge Strengthening n Bridge Repairs

8. DOT-Federal Highway Administration FRP TECHNOLOGY CHARACTERISTICS n High Strength n High Resistance to Corrosion and Chemical n High Resistance to Elevated Temperature n High Resistance to Abrasion n Toughness n Fatigue n Light Weight

9. DOT-Federal Highway Administration FRP TECHNOLOGY ADVANTAGES n Ease in Fabrication, Manufacturing, Handling, and Erection n Year-Round Construction n Short Project Time Delivery n High Performance n Durability (Jury Still Out) n Excellent Strength-to-Weight Ratio

10. DOT-Federal Highway Administration FRP TECHNOLOGY DISADVANTAGES -1 n High First Cost n Creep and Shrinkage n Potential for Environmental Degradation (Alkalis’ Attack, UV Radiation Exposure, Moisture Absorption, etc.) n Consistency of Material Properties

11. DOT-Federal Highway Administration FRP TECHNOLOGY DISADVANTAGES - 2 n Global and Local Buckling n Aerodynamic Instability With Lightweight n Requires Highly Trained Specialists n Lack of Standards and Design Guides n Limited Joining and Connection Technology (Adhesive joints, fasteners)

12. DOT-Federal Highway Administration FRP TECHNOLOGY PUBLIC CONCERNS n Fire/Flame Resistance n Smoke Toxicity n Fuel Spills n Vandalism/Theft n Inspectibility n Repairability

13. DOT-Federal Highway Administration MANUFACTURING PROCESS COMMON TO CIVIL APPLICATIONS n Pultrusion n Filament Winding n Layup

14. DOT-Federal Highway Administration WHAT IS FRP COMPOSITES COMPONENTS n Fiber Reinforcement n Resin Matrix ***(Fiber-Matrix Interphases)*** n Fillers n Additives

15. DOT-Federal Highway Administration FRP TECHNOLOGY MECHANICAL PROPERTIES n Fiber Types n Fiber Orientations n Fiber Architecture n Fiber Volume (30-70%)

16. DOT-Federal Highway Administration FRP TECHNOLOGY FIBER TYPES n Glass n Aramid n Carbon (Graphite) n Boron n Polyvinyl alcohol (PVA) (Available in Japan)

17. DOT-Federal Highway Administration FRP TECHNOLOGY FIBER OREIENTATION n 0 Degree (Parallel - Warp) n 90 Degrees (Transverse - Weft) n Between 0 and 90 Degrees (Biased) n (e.g. 0/45/90/-45/0)

18. DOT-Federal Highway Administration FRP TECHNOLOGY FIBER ARCHITECTURE n Braiding (2D & 3D) n Knitting n Weaving n Stitched n Chopped

19. DOT-Federal Highway Administration FRP TECHNOLOGY CARBON FIBER n Three Polymer Precursors: *Polyacrylonitrile (PAN) *Rayon *Pitch n Anisotropic Materials n Linear Elastic to Failure n Failure by Rupture

20. DOT-Federal Highway Administration FRP TECHNOLOGY ARAMID FIBER n Aromatic Polyamides n Kevlar 29 n Kevlar 49 n Anisotropic Materials n Linear Elastic to Failure n Failure by Rapture

21. DOT-Federal Highway Administration FRP -TYPICAL PROPERTIES Source: Tonen Energy Corp

22. DOT-Federal Highway Administration FRP BRIDGE TECHNOLOGY FIBER PROPERTIES fiber stress (Gpa) fiber strain (%) 1 2 3 4 1234 E-glass (350 ksi) Aramid (500 ksi) Carbon (600 ksi)

23. DOT-Federal Highway Administration FRP TECHNOLOGY RESIN SYSTEM n Thermoplastics (melts when heated, solidifies when cooled, no permanent curing) n Thermosets (cures permanently by irreversible cross linking at elevated temp.)

24. DOT-Federal Highway Administration FRP TECHNOLOGY RESIN FORMULATIONS n Viscosity n Reactivity n Resiliency n High Deflection Temperature (HDT)

25. DOT-Federal Highway Administration FRP TECHNOLOGY RESIN TYPES n Unsaturated Polyesters n Epoxies n Vinyl Esters n Polyurethanes n Phenolics

26. DOT-Federal Highway Administration FRP - RESIN SYSTEM UNSATURATED POLYESTERS - 1 n 75% Resins Used in USA n Condensation Polymerization of Dicarboxylic Acids & Dihydric Alcohols n Contains Maleic Anhydride or Fumaric Acid

27. DOT-Federal Highway Administration FRP - RESIN SYSTEM UNSATURATED POLYESTERS - 2 n Dimensional Stability n Affordable Cost n Ease in Handling, Processing, & Manufacturing n High Corrosion Resistant & Fire Retardants n Best Value for Performance & Strength

28. DOT-Federal Highway Administration FRP - RESIN SYSTEM EPOXIES n Glycidyl Ethers and Amines n Customized Properties n Limited Workability n Sensitive to Curing Agents n High Performance n High First Cost

29. DOT-Federal Highway Administration FRP - RESIN SYSTEM VINYL ESTERS n Good Workability n Fast Curing n High Performance n Toughness n Excellent Corrosion Resistance

30. DOT-Federal Highway Administration FRP - RESIN SYSTEM POLYURETHANES n Polyisocyanate & Polyol n Reaction or Reinforced Injection Molding Process n High Performance n Toughness n Excellent Corrosion Resistence

31. DOT-Federal Highway Administration FRP - RESIN SYSTEM PHENOLICS n Phenols & Formaldehyde n Resole - Alkaline (F/P > 1.0) (Cured by Heat) n Novolac - Acidic (F/P < 1.0) (Cured by Chemical Reaction) n Resistance to High Temperature n Good Thermal Stability n Low Smoke Generation

32. DOT-Federal Highway Administration FRP TECHNOLOGY FILLERS n Control Composites’ Cost n Improved Mechanical Properties n Improved Chemical Properties n Reduced Creep & Shrinkage n Low Tensile Strength n Fire Retardant & Chemical Resistant

33. DOT-Federal Highway Administration FRP TECHNOLOGY FILLER TYPES n Calcium Carbonate n Kaolin n Alumina Trihydrate n Mica Feldspar n Wollastonite n Silica, Talc, Glass

34. DOT-Federal Highway Administration FRP TECHNOLOGY ADDITIVES n Improved Material Properties n Aesthetics n Enhanced Workability n Improved Performance

35. DOT-Federal Highway Administration FRP TECHNOLOGY ADDITIVE TYPES n Catalysts n Promoters n Inhibitors n Coloring Dyes n Releasing Agents n Antistatic Agents n Foaming Agents

36. DOT-Federal Highway Administration FRP TECHNOLOGY SMART MATERIALS n Innovative Design and Application n Customized Product for High Performance n Versatility n Complex Design Process n Materials, Processing, Configurations

37. DOT-Federal Highway Administration FRP - DESIGN FEATURES n Avoid Abrupt Thickness Change n Take Advantage of Geometric Shapes n Take Advantage of Hybrid System n Use Bonded Assemblies & Joints n Provide Good Details on Connections

38. DOT-Federal Highway Administration FRP - DESIGN AVOID ABRUPT THICKNESS n Inefficient By Thickness n Avoid Stress Risers n Consider Stress Flow n Consider Load Paths n Understand Structural Behavior

39. DOT-Federal Highway Administration FRP - DESIGN FEATURES n Avoid Abrupt Thickness Change n Take Advantage of Geometric Shapes n Take Advantage of Hybrid System n Use Bonded Assemblies & Joints n Provide Good Details on Connections

40. DOT-Federal Highway Administration FRP - DESIGN GEOMETRICAL SHAPES n Low Stresses n Optimize Design - Balance Criteria (Stress, Deflection, and Stability) n Use Flanges, Ribs, Stiffeners n Use Honeycomb or Box Cells, Tubes n Proportioning and Orienting Cells

41. DOT-Federal Highway Administration FRP - DESIGN FEATURES n Avoid Abrupt Thickness Change n Take Advantage of Geometric Shapes n Take Advantage of Hybrid System n Use Bonded Assemblies & Joints n Provide Good Details on Connections

42. DOT-Federal Highway Administration FRP - DESIGN HYBRID SYSTEMS n High Strength in Composites n High Stiffness in Conventional Materials n Concrete Filled Carbon Shells n Reinforced Timber Beams n PS Tendons, Rods, Bars, Laminates n Account for Material Compatibility

43. DOT-Federal Highway Administration FRP - DESIGN FEATURES n Avoid Abrupt Thickness Change n Take Advantage of Geometric Shapes n Take Advantage of Hybrid System n Use Bonded Assemblies & Joints n Provide Good Details on Connections

44. DOT-Federal Highway Administration FRP - DESIGN BONDED JOINTS n Epoxy Bonded Assemblies n Epoxy Bonded Joints n Bonded Shear Transfer Strips n Plate Bonding Technology n Bonded Splices n Durability of Joints

45. DOT-Federal Highway Administration FRP - DESIGN FEATURES n Avoid Abrupt Thickness Change n Take Advantage of Geometric Shapes n Take Advantage of Hybrid System n Use Bonded Assemblies & Joints n Provide Good Details on Connections

46. DOT-Federal Highway Administration FRP - DESIGN CONNECTION DETAILS n Local Stress Flow n Overall Load Path n Weak Links n Manufacturing Defects n Fabrication Irregularities n Select Proper Fasteners

47. DOT-Federal Highway Administration FRP TECHNOLOGY FUTURE DEVELOPMENTS n T 2 from Aerospace Industry - CE transition n Bridge structures - Stiffness Driven n Customized vs. Open Market n Cross Cutting Team in Design-Build n Education and Training of SE/CEs n New Construction Technology n New Manuf./Fabric. Technology

48. DOT-Federal Highway Administration FRP TECHNOLOGY CONCLUSION - 1 n Continue R & D Activities n Training n Government & Private Funding n Building Teamwork & Partnership n Proprietary Products & Patents n Performance/Prescriptive Specs - “Birth Certificate” & Baseline Reference

49. DOT-Federal Highway Administration FRP TECHOLOGY CONCLUSION - 2 n AASHTO, ASCE, ACI, PCI, n NSF, NIST (ATP), ISCC n Euro and Japanese Standards (Std.) n Design Std., Specs & Guidelines n Materials Specifications & Testing Std. n Manufacturing Process & Standards n Database Management