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PIANCInCom WG Reportn 191 - 2020COMPOSITES FOR HYDRAULIC STRUCTURESThe World Association for Waterborne Transport Infrastructure
PIANCThe World Association forWaterborne Transport InfrastructurePIANC REPORT N 191INLAND NAVIGATION COMMISSIONCOMPOSITES FOR HYDRAULIC STRUCTURES2020
PIANC has Technical Commissions concerned with inland waterways and ports (InCom),coastal and ocean waterways (including ports and harbours) (MarCom), environmentalaspects (EnviCom) and sport and pleasure navigation (RecCom).This report has been produced by an international Working Group convened by the Inland Navigation Commission (InCom). Members of the Working Group represent severalcountries and are acknowledged experts in their profession.The objective of this report is to provide information and recommendations on goodpractice. Conformity is not obligatory and engineering judgement should be used in itsapplication, especially in special circumstances. This report should be seen as an expertguidance and state-of-the-art on this particular subject. PIANC disclaims all responsibility in the event that this report should be presented as an official standard.PIANC Secrétariat GénéralBoulevard du Roi Albert II 20, B 3B-1000 BruxellesBelgiquehttp://www.pianc.orgVAT BE 408-287-945ISBN 978-2-87223-006-8 All rights reserved
TABLE OF 124.134.14General Aspects .5Introduction .5Objective . 5Structure of the Report .5Related PIANC Reports .6Members of the Working Group .6WG 191 Meetings.8Potential Impact of the Guidance .8Terms of Reference.8Acknowledgements .8Introduction to Composites . 9Introduction .9FRP Constituents .92.2.1Fibres .92.2.2Resins .92.2.3Additives and Other Ingredients . 10Manufacturing of Composites . 102.3.1Pultrusion . 102.3.2Resin Transfer Molding . 112.3.3Vacuum-Assisted Resin Transfer Molding . 122.3.4Wet Lay-Up/Hand Lay-Up . 122.3.5Compression Molding . 12Composites Properties . 13Applications . 13Characteristics and Failure Modes of Composites . 15Characteristics of Composites . 153.1.1High Strength-and Stiffness-to-Weight Ratio . 153.1.2Durability . 153.1.3Long-Term Water Submersion Resistance . 163.1.4Chemical Resistance . 163.1.5Ultraviolet Resistance . 173.1.6Thermal degradation . 173.1.7Hydrothermal . 173.1.8Low Temperature and Freeze-Thaw (FT) Cycling . 173.1.9Fire Resistance (FR) . 183.1.10Fatigue Evaluation . 18Types of Failures . 203.2.1Failure of Polymer Composites. 203.2.2Failures from Process and Production Variabilities . 213.2.3Failures under Environmental Variations . 22Recycling and Green Composites . 23Concluding Remarks . 23Hydraulic Structural Applications: Case Studies . 24Mitre Blocks . 24Underwater Wrapping of Concrete Ports. 25Wicket Gates . 26Recess Panels . 27Rehab of Corroded Steel Piles . 28Lock Gates and Stop Logs . 29Structural Repair and Protection System . 31Composite Dolphin . 32Composite Lighthouse. 33SuperLoc Fibreglass Reinforced Polymer (FRP) Sheet Piling and Accessories . 34Composite Pilings Protect Platinum LEED Site from Flooding . 34Composite Pilings Alter Course of Erosion . 35Fibreglass Structures Stand the Test of Time Offshore. 35Fibreglass Structures Used to Reclaim Beaches . 361
FRP Products Aid in the Rehabilitation of Endangered Species . 36Materials Guard a California Pier from Corrosion . 37FRP Arctic Towers Project . 38DURADEK in Olympic Pool Operation . 38Fibreglass Floating Docks Save High Maintenance Costs . 39Fibreglass Grating Stays Shipshape Longer . 39DURADEK Platforms and Catwalks Save LaGuardia Millions in Maintenance Costs . 40Fibreglass Fights Corrosion ‘Underwater’ and Above . 41Phenolic Grating- Lightweight Offshore Decking . 41Movable Pool dividers that are Long-Lasting . 42Strongwell’s Pultruded Grating for a Florida Marina . 42Round Safrail . 43SAFPLANK – The Ideal Material for a Pier Deck . 44STRONGDEKTM Ocean Front Fibreglass Decking Impervious to salt water Environment . 44Glass Fibre Reinforcement by ComBAR . 45Panels, Pipes and Posts . 46Pont y Ddraig (Bridge of the Dragon) Foryd Harbour . 46Large-Scale Composite Bumper System for Bridge Pier Protection Against Ship Collision . 47Reinforced Plastic Inspection Walkway . 47Hoover Dam Penstock Tunnels . 48Drop Protection for Subsea Applications . 49Bellagio Hotel and Casino Fountains . 49Aids to Navigation (ATON) Structures . 50Subsea Cocoons . 50Concluding Remarks . 51Design METHODS FOR Composite Structures . 52Introduction . 52Overview of Development of American FRP Standards . 52Overview of Development of European FRP standards . 53Reduction Factors Used in Pre-Standard for Load and Resistance Factor Design (LRFD) of PultrudedFibre Reinforced Polymer (FRP) Structures . 535.5Design of FRP Recess Panel . 545.6Design of FRP Wicket Gate . 545.7Design of FRP Blocks for Mitre Gates . 575.8Repair of Corroded Steel Piles with FRP . 585.9Design Steps of a FRP Composite Lifting Gate . 605.9.1Introduction . 605.9.2Design Requirements and Assumptions . 615.9.3Material Selection . 615.9.4Structural Concepts . 615.9.5Deflection Requirements . 625.9.6Cost Comparison . 625.10 Concluding Remarks . Inspection and Maintenance . 63Infrared Camera and Heating System . 63Digital Tap Hammer . 64Fibre Optical . 65Sample Field Testing Results . 65Repair and Maintenance . 66Concluding Remarks . 66Cost Considerations. 67Need for Cost Analysis . 67Methods of Cost Analysis . 677.2.1Initial Costs . 677.2.2Life Cycle Costs. 67Case Study: Initial Future Cost for FRP Bridge Decks . 69Case Study: LCC Analysis on FRP Bridge Deck Applications . 69USACE Experiences . 69Europe Experience . 712
7.7Conclusions. 71SUMMARY . 72REFERENCES . 73APPENDIX A: GLOSSARY OF TERMS . 85APPENDIX B: OUTSTANDING TECH PAPER AT CAMX 2019. 89LIST OF FIGURESFigure 1.1Group photo of WG 191 members who attended the June 2017 meeting in the Netherlands. Left to right:Jonathan, Martijn, Jos, Wouter, Liesbeth, Hota and John.Figure 2.1Pultrusion of 4’ Wide GFRP Composite Sandwich Panels with Integral Joint EdgesFigure 2.2RTM processFigure 2.3Compression molding processFigure 2.4Thirty-five (35) tonnes CFRP of fuselage, wings, tail, gates and interior are used in each 787Figure 2.5Ocean Gate (Everett, WA, US) announced on 27 June 2019 the successful unmanned depth test of themanned submersible, Titan, to validate the hull to a depth of 4,000 m (13,123 ft)Figure 2.6Startlink House. Startlink is a pultruded glass reinforced composite component kit which can be rapidlyassembled into a wide variety of low-rise building forms without metal fasteningsFigure 3.1Cracking initiation and growth of a sandwich sample under 3 pt bending fatigue, leading to eventualfailure at the corner (WVU-CFC)Figure 3.2Different shapes of composite structuresFigure 3.3Honey-comb structureFigure 3.4Sandwich laminate failure modes (adapted from Det Norske Veritas Offshore Standard DNV-OS-C501,Composite components, 2003)Figure 4.1Mitre gate (left); Mitre block (right)Figure 4.2Single GFRP Block (4" 2.5", 55 % fibre volume) with Max. Failure Load 224 (kips)Figure 4.3View of Discharge Ports at Chickamauga Lock and Dam, TNFigure 4.4(a) Aqua Wrap; (b) Onboard Audio, Video, and Depth Monitoring; (c) Under WaterFigure 4.5Deteriorated Wood Wicket Gate Pulled from ServiceFigure 4.6Composite Wicket Gate (Left) and Prototype Gate under BendingFigure 4.7Composite Wicket Gates in ServiceFigure 4.8(a) Steel Recess Panel; (b) FRP SuperDeck Component; (c) SuperDeck with Polyuria Coating; (d)Assembly with Steel FrameFigure 4.9East Lynn Bridge Rusted and Scoured at MudlineFigure 4.10 Rehabilitation Steps of Steel Piles with FRP CompositesFigure 4.11 Werkendam FRP Lock GatesFigure 4.12 Erica Ter Apel Lock Gates (Provinces Groningen & Drenthe, the Netherlands)Figure 4.13a World’s Largest FRP Lock Gates in the Wilhelminakanaal TilburgFigure 4.13b The FRP lock gates in the WilhelminakanaalFigure 4.13c Flood protection FRP lifting gate at ‘Afsluitdijk' fish passageFigure 4.14 FX-70 Structural repair and protection system of Simpson strong-tieFigure 4.15 Before (left) and after (right) foundations repairs of Chesapeake Bay BridgeFigure 4.16 FRP Dolphin (Fuerteventura, Canary Islands, Spain, 2014)Figure 4.17 FRP lighthouse in the north extension of Valencia Port (Valencia, Spain,2015)Figure 4.18 CMI’S UltraCompositeTM UC 95 profile sheet piling for flood wallFigure 4.19 Walls made of UltraCompositeTM UC 30 sheetsFigure 4.20 All-fibreglass well bay deck for 18 wellheads on Shell’s Southpass 62A production platformFigure 4.21 The Martin Beach Builder , a new triangular framing system anchored to a precast concrete baseFigure 4.22 FRP lifting and lowering platform made from Strongwell products to rehabilitate the manateesFigure 4.23 The Avila Beach Pier in California reconstructed using Strongwell’s pultruded fibreglass structuralmaterialsFigure 4.24 FRP arctic towers for a Seal Observation Facilities Project on St. Paul Island, AlaskaFigure 4.25 The Olympic pool in Oklahoma City, OklahomaFigure 4.26 Fibreglass floating docks in Snohomish County, Washington StateFigure 4.27 Fibreglass grating manufactured by Strongwell used by Delta Marine, Seattle, WA.Figure 4.28 DURADEK platforms and catwalks3
Figure 4.29Figure 4.30Figure 4.31Figure 4.32Figure 4.33Figure 4.34Figure 4.35Figure 4.36Figure 4.37Figure 4.38Figure 4.39Figure 4.40Figure 4.41Figure 4.42Figure 4.43Figure 4.44:Figure 4.45Figure 5.1Figure 5.2Figure 5.3Figure 5.4Figure 5.5Figure 5.6Figure 5.7Figure 5.8Figure 5.9Figure 5.10Figure 5.11Figure 5.12Figure 5.13Figure 5.14Figure 5.15Figure 5.16Figure 5.17Figure 6.1Figure 6.2Figure 6.3Figure 6.4Figure 6.5SAFRAILTM fibreglass handrail systems used in the Mall of America'sDURAGRID phenolic grating used in Shell Mars tension leg platform in the Gulf of MexicoMovable swimming pool divider bulkheads, manufactured by Recreation Supply CompanyStrongwell’s DURAGRID T-1700 pultruded grating used on piers at Dinner Key Marina in Miami, FloridaStrongwell’s round SAFRAILTM industrial handrail system in Fort Lauderdale, FloridaStrongwell’s SAFPLANK fibreglass plank system for the pier’s deckSTRONGDEKTM installed at Perdido Beach Resort in Orange Beach, AlabamaGlass Fibre Reinforcement by ComBAR (Fibreline Composite)FRP Handrail, Ladder, Platform and Walkway for Sea Waterfront FacilitiesCycle/Footbridge across the River Clwyd at Rhyl Harbour, North WalesApplications of LCBS on bridge protection projects in ChinaBlennerhassett Island BridgePROForms structural fibreglass shapesPROForms fibreglass structural shapes and PROGrid fibreglass molded grating panelsBellagio Hotel and Casino fountainUSCG Aids to Navigation (ATON) built using FRP piles. (USCG) (LT Jon Benvenuto, P.E. and DanO’Connor, P.E. Composite Material in U.S Coast Guard Aids to Navigation)Subsea CocoonsFRP hexagonal super-deckFRP super-deck under 3-point loadingHorse-type wicket gate configuration (left), timber wicket gate (right)Wicket gate in operating positionTop bail (left) and bottom bail (right)Cross section of the FRP wicket gate (dimensions are in inches, 1 inch 25.4 mm)Four-point bending test of FRP wicket gateOperating position of the gateMitre gateMitre block spaceEast Lynn Lake Bridge: corroded steel piles, Cove Creek, WV, USAClose-up of corroded steel pileClose-up of shell placed around corroded steel pileDiagram of the repairs that will encapsulate and protect the piles from future corrosionColumns with shells in placed and wrapped with GFRP wrapView of the bridge after rehabilitation (Photo by Dale Smith)Overview of the storm surge barrier with gatesInfrared testing equipment – (a) low cost infrared camera (b) advanced infrared camera and (c) shopheaterAdvanced infrared testing equipment including pulsed and flashed heating and data processing computerDigital tap hammerDigital picture and (b) infrared image of the inner side of outer west beam in Muddy Creek BridgeDigital picture and corresponding infrared images of various debonded areas in the La Chein GFRPbridge deckLIST OF TABLESTable 1.1 Related PIANC reportsTable 2.1 Comparison in properties between FRP composites and other materialsTable 5.1 Adjustment factors for end-use conditions (extract from Draft LRFD code)Table 5.2 Mechanical properties of FRP hexagonal super-deckTable 5.3 Four-point bending test results of FRP wicket gate4
Figure 4.32 Strongwell's DURAGRID T-1700 pultruded grating used on piers at Dinner Key Marina in Miami, Florida Figure 4.33 Strongwell's round SAFRAILTM industrial handrail system in Fort Lauderdale, Florida Figure 4.34 Strongwell's SAFPLANK fibreglass plank system for the pier's deck
