8th International Conference on Structural Engineering and Construction Management, 2017

ICSECM2017-70

EFFECTS OF BONDING TECHNIQUES ON THE SHORT TERM PERFORMANCE OF

CFRP STRENGTHENED CORRODED STEEL MEMBERS
U.N.D. Perera1*, J.C.P.H. Gamage 2
1Postgraduate, Department of Civil Engineering, University of Moratuwa, Sri Lanka
2Senior Lecturer, Department of Civil Engineering, University of Moratuwa, Sri Lanka
*Correspondence E-mail: kgamage@mrt.ac.lk, TP: +9477384 4261
Abstract: Most of the existing metallic structures around the world are in need of
strengthening/restoration due to the effect of corrosion. Use of Carbon Fibre Reinforced Polymer
(CFRP) materials to strengthen steel members is an excellent solution. However, the contact
between CFRP and steel may lead to galvanic corrosion during the service life. In the present
study, different bonding techniques to enhance the composite performance while avoiding
contact with the substrate was investigated. Double strap joints with different bonding
techniques were prepared and tested. The results clearly indicate the dependency of bond
performance with the selected bonding technique.
Keywords: Steel; Strengthening; CFRP; Corrosion; Bond Performance

1. Introduction strength/weight ratio, weather and

Corrosion is one of the main causes of the
deteriorated steel infrastructures in the
world. The Civil Engineering field
particularly suffers due to these rusted
structures which will ultimately reduce the
operational requirements and risk the public
safety. On the other hand, the resources
show that the worldwide corrosion cost is
over one Trillion and almost half of the
existing metallic structures in the world are
required to be restored/strengthened [01].
However, repairing the structural elements
could be much more cost-effective than the
partial/complete restoration of the
members. Therefore, several strengthening
schemes such as attaching a steel plate,
external post-tensioning and steel jacketing
etc. [02, 03] have been introduced in order to
increase the load-bearing capacity of those
structures. Due to the unfavourable
conditions of these methods such as the
requirement of expensive false-work, labour
and difficulties in transportation and
handling heavy steel plates, engineers often
explored for alternative methods [04, 05].
One such method of repairing degraded steel
structural elements is by bonding (CFRP)
Carbon Fibre Reinforced Polymer material
which has already become a promising
strengthening technique for naval, aero and
Civil Engineering concrete structures.
Desirable physical/mechanical properties of
the CFRP material such as high
corrosion resistance, excellent fatigue
performance, ease of handling etc. and
overcoming the drawbacks found in
traditional methods, make this technique
more effective. Hence, research studies on
evaluating the effectiveness of this
strengthening technique have gained more
attention nowadays.
As the weakest link of this strengthening
technique is the bond between the steel
substrate and the CFRP material, it is
essential to understand the bond behaviour
for the durability and the reliability of this
system. Even though there are many
research studies available which are focused
on the bond strength evaluation under
different environmental and/or loading
conditions [6-12], most of them have used
non – corroded steel plates for the testing.
This does not take into account the surface
characteristics of corroded steel surfaces
which can govern the bond strength between
the two substrates. However, some studies
have focused on the bond performance of
CFRP strengthened, heavily corroded steel
girders and revealed its effectiveness in
increasing the strength and stiffness while
decreasing the strain development of those
deteriorated beams [13,14]. Elchalakanni et
al [01] performed a series of experiments to
determine the flexural and bearing strength
of CFRP strengthened Circular Hollow
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Sections (CHS) by taking into account length of the test specimens was determined
different levels of rust. by carrying out a series of experiments with
varying bond lengths and it was found out to
Further, exposed environmental conditions
be 115 mm. Hence, L1 and L2 were taken as
are one of the most influential factors for the
115 mm and 120 mm separately. All the
bond strength and the durability
samples were tested in tension by 1000 kN
performance. Galvanic corrosion is one such
Universal Testing Machine for the bond
destructive result caused in aggressive
strength evaluation.
environments when there is a direct contact
between the Carbon fibres and the steel plate L1 L2
in the presence of an electrolyte with a
Joint
sufficient conductivity. The literature
suggests preventing the contact in between a
CFRP/Steel joint by introducing a non –
conductive barrier [04]. Providing a GFRP Steel plate
CFRP Adhesive
(Glass Fibre Reinforced Polymer) is
layer
recommended by many a research studies as Layer
(Side View)
it provides an additional benefit of strength 38 mm
enhancement as well [04, 13, 14].
The current research study is carried out to
determine the bond strength enhancements
of CFRP/Steel joints with a presence of an 324 mm
interfacial barrier layer in between CFRP and (Plan View)
steel by considering surface roughness of Figure 1: Schematic figure of a typical double
corroded steel plates. In this regard, a layer strap joint
of GFRP and a commercially available 2.1 Material Properties
polymer mesh had been utilized to avoid
direct contact between CFRP and steel. Six Corroded steel plates used for the double
number of bonding techniques were strap joint specimens were having a
considered for the make of double strap thickness of about 5 mm average. Araldite
joints and total of 12 steel/CFRP joints were 420 A/B was the adhesive used for the
tested in direct tension for the bond strength bonding of strengthening sheets. Mechanical
evaluation. properties of the materials used in the
investigation were tested according to the
2. Test Program relevant ASTM standards and the obtained
A total 12 number of double strap joints were results are summarized in Table 01.
prepared with 6 different bonding Table 01: Material Properties
configurations. A schematic diagram of a
double strap joint with the relevant Mechanical Elasticity Ultimate Thickness
dimensions is shown in figure 01. Naturally Property Modulus Tensile (mm)
corroded steel plates chosen for the (GPa) Strength
experiments were having slight pits and mill (MPa)
scale has rusted away. Surface roughness Steel 193 508 5
parameters of a steel plate were found to be
Adhesive 1.495 30.13 <1
as follows; 2.02 με and 10.215 με of arithmetic
mean heights of the sampling length (Ra) and CFRP 175.6 1575 0.166
the irregular surface (Sa) respectively, 7.9 με GFRP 76 2300 0.36
and 104.0 με of maximum height difference
(manufacturer
of the profile length (Rz) and the surface (Sz)
respectively, 2.42 με and 13.6 με of root mean provided)
square heights of the profile length (Rq) and
2.2 Sample Preparation
the surface (Sq) respectively. Effective bond
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Surface preparation of the steel plates was
achieved by grinding away the rust and
other contaminants on the steel substrate.
2 (a) 2 (b)
2 (c) 2 (d)
Figure 2: (a & b) corroded plate before and after
surface preparation (c & d) relevant SEM
images respectively
Figure 02 shows a prepared and a non –
prepared steel surface and their relative SEM
(Scanning Electron Microscopic) images.
Soon after the surface preparation, a primer
layer was applied in order to protect the
surface before the CFRP bonding and
improve the bond strength as well as the
durability. After minimum of 6 hour curing
time, double strap joints were made in six
different bonding arrangements as described
in figure 03: (a) CFRP only, (b) GFRP only,
(c) Polymer mesh only (d) GFRP layer
embedded in between steel and CFRP (e)
Polymer mesh embedded in between steel
and CFRP and (f) CFRP layer sandwiched in
between GFRP layers. Wet–lay–up method
was used for the adhesive bonding. All the
FRP and polymer layers are saturated with
an adhesive layer and it is not shown in
figure (3) for clarity.
3. Results and Discussion
Table 02 shows the summary of the results
obtained for the CFRP/steel joints which
were tested in direct tension. The double
strap joints made only out of a single layer of
CFRP (C – 01 & 02) and GFRP (G – 01 & 02)
are showing a similar test result of about
CFRP layer GFRP layer
Steel
3 (b) GFRP only
3(a) CFRP only
(“G” type)
(“P” type)
Polymer CFRP layer
GFRP layer
Mesh
3 (c) Polymer Mesh 3 (d) Single layer of
only (“P”type) both GFRP & CFRP
(“GC”type)
CFRP layer GFRP layers
Polymer Mesh CFRP layer
3 (e) Single layer of 3 (f) CFRP layer
both Polymer mesh sandwiched with GFRP
and CFRP (“PC” type) layers (“GCG” type)
Figure 03 (a,b,c,d,e,f): Bonding Configurations
24.75 kN. Both of these joints were failed due
to steel/ adhesive interface debonding and
hence the maximum capacity of the FRP
sheets had not been profited. As the
corroded surface was only partially cleaned
to remove the rust layers, remained
contaminants and the fairly smooth surface
may have been the cause for this failure
mode.
The joints bonded with only a polymer mesh
(P – 01 & 02) failed at a very low load due to
the ruptured polymer sheet at the location of
the joint. When the Polymer sheet was used
as the interface barrier between the steel and
the CFRP sheet (PC 01 & 02), a strength
increment of about 24.6% was observed over
the joints with only CFRP (C 01 & 02).
However, a mixed mode failure was
determined as mentioned in Table 01 which
concludes a complex nature of the failure.
CFRP bonded steel plates with a GFRP
barrier interface (GC 01 & 02) gained a
strength increment of about 83.2% over “C”
type joints and somewhat similar percentage
of increment was obtained for “GCG” type
joints as well. The failure mode of the all
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Table 02: Summary of the results prediction when the number of strengthened
layers is increased.
Bonding Ultimate Average Failure Mode
Technique Load Ultimate The main objective of using a polymer mesh
Load
(kN) in between two substrates was only to
(kN)
incorporate a barrier layer to prevent the
01. C – 01 24.75 Steel/Adhesive direct contact of Carbon fibres with the steel.
interface de- Therefore, a commercially available polymer
02. C – 02 27.15 25.95 bonding and
CFRP
mesh of about 1 mm thickness had been
delamination used. Yet, using GFRP layers fulfils this
03. G – 01 22.05 requirement with an additional strength gain
Steel/Adhesive to the strengthened system. Therefore, it can
23.55 interface de-
04. G – 02 25.05
bonding
be further concluded the use of GFRP is
preferred, as recommended by several
05. P – 01 5.75 research studies [04], considering the short
5.55 Fibre breakage
term bond performance results obtained
06. P – 02 5.35 from the current research.
60 C
07. GC – 43.85
Steel/Adhesive G - 01
01 50 G - 02
47.53 interface de-
08. GC – 51.20 PC - 01
bonding 40
Load (kN)

02 PC - 02
30 GC - 01
09. PC – 01 34.70 Mixed modes of
GC - 02
Steel/Adhesive GCG - 01
20
interface de- GCG - 02
10. PC – 02 29.95 bonding, FRP 10
rupture,
interface 0
delamination 0 2000 4000 6000 8000 10000
32.33 between CFRP Microstrain (με)
and Polymer
mesh, Cohesive Figure 04: Strain variation of double strap joints
failure between
Strain measurements were obtained by the
steel and
Polymer mesh, strain gauges attached at the locations of 60
CFRP and mm away from the joint. Figure (04) shows
Polymer mesh the strain variations of all types of
11. GCG – 53.60 CFRP/Steel joints except for “P” type since
01 Steel/Adhesive
47.05 interface de- the obscurity occurring due to the
12. GCG – 40.50
02 bonding comparatively lower ultimate strength. An
extreme nature of ductile failure was
GC and GCG type joints were limited to observed for both “P” type specimens at the
steel/ adhesive interface debonding. No joint location. Similar strain variation pattern
delamination between intermediate FRP can be seen for both “C” type and “G” type
sheets was seen as some of the observations specimens while higher average strain
of past researchers who used more than a values were prominent for “GC” and “GCG”
single layer of FRP layers [15]. Moreover, type of joints. One of the noticeable
negligible strength enhancement of GCG observation is the increased chances of
type joints over GC type joints can be occurring a sudden brittle failure with the
attributed to the fact of increased chance of increased FRP layers which is true for all
bond failure with the increased FRP “GCG” type of joints.
thickness [16]. On the other hand, the
highest standard deviation within the similar 4. Conclusion
type of joints was seen in GCG type joints Naturally corroded steel plates were used to
deducing an uncertainty of the failure investigate the short-term bond performance
 8th International Conference on Structural Engineering and Construction Management, 2017
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of CFRP strengthened double strap joints. Six
different bonding configurations were
considered to prevent possible galvanic
corrosion effects by providing an
intermediate barrier layer and evaluate the
bond strength enhancement.
01. Both “G” type and “C” type joints were
seen to be having a similar joint strength and
both of these specimens failed due to
steel/adhesive interface de-bonding which
does not occupy the fullest capacity of the
FRP sheets.
02. Use of a Polymer mesh in between the
two substrates (CFRP and Steel) could
enhance the joint capacity for about 25%.
However, a vast range of failure modes was
observed during the testing.
03. Bond strength attained from the
bonding arrangement which sandwiched a
CFRP layer in between GFRP layers (GCG
Type) showed more or less same as that of
“GC” type specimens and it was about 83%
of strength enhancement over “C” type
joints. “”GCG” type of specimens were made
with the intention of providing an insulation
for the CFRP layer. However, there was no
benefit with respect to the joint strength and
moreover, it increases the chances of a brittle
failure.
04. Long-term performance analysis
should be carried out in order to study the
capacity of these intermediate layers to
prevent galvanic corrosion in an adverse
environmental condition.
05. The current research considered merely
a minimum surface preparation level taking
into account such cases where fully cleaned
surface preparation could not be achieved.
Further studies should be performed using a
sizing agent [04] and silane application [15]
as recommended by some past research
studies.
Acknowledgements
The authors sincerely acknowledge the
Senate Research Committee (SRC) for
providing the necessary financial support;
Grant No. SRC/LT/2016/19. Airow
Solutions (Pvt) Ltd is also acknowledged for
the publication support. Mr. D.M.N.L
Dissanayake and the staff from Structural
testing laboratory, Department of Civil
Engineering, University of Moratuwa, Sri
Lanka are also gratefully acknowledged.
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