Behavior of Externally Draped CFRP Tendons in Prestressed Concrete Bridges Nabil F. Grace Ph.D., P.-E. Professor Civil Engineering Department Lawrence Technological University Southiield, Michigan George Abdel-Sayed Dr. Eng,, PE. Professor Civil and Environmental Engineering Department University of Windsor Windsor, Ontario, Canada Successful use of carbon fiber reinforced polymer (CFRP) tendons in prestressed concrete bridges can be achieved by combining bonded internal tendons with unbonded externally draped tendons. To examine this theory, four bridge models were tested under static, repeated (7 million cycles), and ultimate loads. Also, the combined effects of factors such as: (a) draping angle; (b) deviator diameter; (c) number of attached die-casts used to anchor the tendons; (d) presence of cushioning material between the deviator and the tendon; and (e) twist angle on the strength of the tendons were ‘examined. It was concluded that the use of externally draped CFRP tendons in bridge construction improves ductility and forces the concrete to undergo inelastic deformation resulting in compression failure. It is also noted that increasing the deviator diameter and using cushioning material at the deviators minimize the reduction in the breaking force of the draped tendon. xternal post-tensioning is pop. E cists ir snavesn pretensioned concrete bridges. In externally prestressed bridges, sev- eral advantages can be realized, in- cluding: (a) reduction in the width of the concrete girders; (b) accessibility for inspection, adjustment, and re- placement of damaged tendons; and (©) reduction in prestressing force losses. Combining these advantages and the known shortcomings in the mechanical properties of the carbon fiber reinforced polymer (CFRP) ten- dons would promote the use of these tendons in external (unbonded) pre- stressing applications An earlier investigation’ indicated that the presence of a deviator at the midspan significantly increased the moment-carrying capacity and the ductility of prestressed concrete beams. In 1997, Manabe et al’ found no differences in the cracking load and ultimate strength of T-girders that had been externally prestressed with steel or carbon/aramid fiber reinforced polymer (CFRP/AFRP) tendons. Inter- estingly, all of their tested beams failed due to concrete crushing. The effect of fatigue loading on the use of extemal AFRP tendons was examined by Saeki et al’ They determined that fatigue loading applied at 33 percent PCI JOURNALInternal CFRP Tendons ‘Tendon Deviator ‘Transverse CFRP Tendon Extemal Draped CFRP Tendon Fig. 1, Elements of CFRP exterallyinternally prestressed bridge system of the ultimate load for 2 million ey- cles had an insignificant effect on the rigidity of the tested beams, ‘At a recent international meeting held in Sapporo, Japan (1997), dis- cussion centered on whether fully bonded or perfectly unbonded applica tions alone were sufficient to maxi- mize the benefits of CFRP tendons in prestressed concrete structures. Re- searchers suggested that partially bonded tendons along the entire span of the girder would be the optimum ar- rangement for these types of materials. However, the authors believe that to achieve the best results in the design of a prestressed concrete bridge using CERP materials, a combination of bonded internal tendons with exter- nally draped (unbonded) tendons should be adopted. To investigate this claim, four bridge models were con- structed and tested under static, re- peated and ultimate loads. ‘The first and second models were right angle bridges whereas the third and fourth models were skew bridges. ‘September-October 1996 Unbonded internal and externally draped tendons were used in the con- struction of the first bridge model, For the second and fourth bridge models, longitudinal internal CFRP rods were grouted and internal transverse rods were not grouted. However, in the third model all longitudinal and trans- verse CFRP rods were grouted, Multi- ple CERP rods were used as externally draped tendons in the second, third and fourth bridge models as shown in Fig. 1 In addition to the experimental pro- ‘gram conducted at Lawrence Techno- logical University (LTTU), the effect of combining several factors on the strength of the tendons was examined by the manufacturers and is reported here. These factors were: (1) tendon draping angle; (2) deviator diameter; (3) number of die-casts installed around the tendon to protect it from damage due to stress concentration at the anchor; (4) presence of the cush- ioning material between the deviator and the tendon; and (5) twist angle (oc- curring during the post-tensioning pro- cess due to the use of couplers). The tests were conducted by pulling the tendons, after imposing different com- binations of those factors, until failure. The effects of the above mentioned factors are discussed below. Effect of Double Die-Casting on CFCC Strength Die-casts are necessary for anchor ing the CFCC (carbon fiber composite cables) tendons, as shown in Fig. 2. Three different configurations of die~ casts were tested, The first consisted of CFCC tendons with a single die- cast at each end. Double die-casts were also tested while pulling on ei- ther the outer or the inner die-cast. Nine tendons were tested, three of each configuration. Table 1 shows the results of the tests. ‘As shown, a single die-cast at each end provided the highest breaking force. Meanwhile, pulling on the outer die-cast of a double die-cast tendon 9Fig. 2. Die-cast for anchoring CFCC tendons. showed the lowest breaking force. The reduction in average breaking force due to pulling on the outer die-cast was 19.8 percent while the reduction due to pulling on the inner die-cast was only 9.0 percent Effect of Draping Angle on CFCC Strength Besides the draping angle effect, two other parameters were consid- ered: (1) deviator diameter (where Table 1. Effect of double die-cast of CFCC prestressing tendons. (Anchorage type: wedge system with die-cast) Treaking force | Average breaking Specimen Case of testing ips kN) force, kips (kN) rec 1x7 382(1700) 125 mm (Vs in) 1 359 (160.0) 38.1 169.6) 4021790) 305 (135.7) 1 307 (1367) 30.6 (1362) 30.6 (1362) 3460539) ut 34.4(1529) M48 (158) 353.1373) (Case I: Double iesasipaling en cuerdie Table 2. Effect of draping angle of CFCC 1 x 7 (12.5 mm) prestressing tendons, [Deviator diameter D = 2.0 in, (50.8 mm) and tendon diameter d= 0.5 in, (12.5 mm), Did = 4; anchor type: resin illing-system with lock nut} ] Reduction in Drapingangle | Test | Breakingforce Average breaking | breaking force (degrees) | number | Kips (kN) force kips (kN) (percent) ° 1 368.1638) 3681638) ° 1 29.1 (1296) 3 z 31.4(1399) 29.6(132.2) 19 3 2851270) 1 235 (1045) 3 2 24.1 (107.1) 240 006:5) M Zz 243 (1080) 90 the tendon touches the deviator) and (2) cushioning the tendons at the de- viators. Table 2 shows the results when using a 2.0 in, (50.8 mm) dev ator diameter for draping angles of 0, 3, and 5 degrees, while Table 3 shows the results for a 20.0 in. (508 mm) deviator diameter and draping angles of 0, 5 and 10 degrees. Exam- ination of these two tables indicates that draping the tendon significantly reduces its breaking force. Larger draping angles lead to a lower break- ing force, It is evident that increasi ator diameter significantly minimizes the large reduction in breaking fore: Only a 12 percent reduction was ob- served for a deviator diameter of 20.0 in. (508 mm), compared to a 34 per- cent reduction for a deviator diameter of 2.0 in. (50.8 mm), with the same draping angle of 5 degrees. Cushioning the tendon at the devia- tor had a significant effect on the breaking force. While a 26 percent re- duction in breaking force was noticed for the uncushioned tendon, only a 9 percent reduction was observed for a cushioned tendon with a draping angle of 10 degrees. These results suggest that the use of cushioning ma- terial and large deviator diameters should be seriously considered when CFCC cables are used for externally draped tendons. the devi- Effect of Draping Angle on CFRP Leadline Rods A small angle of twist in the CFRP Leadiine rods is likely to oceur dur- ing assembly of the anchor head, coupler, and during prestressing. The arrangement of the anchor system of the CFRP Leadline rods is shown in Fig. 3. The influence of the angle of twist with and without the draping effect of the CFRP Leadline rods is shown in Table 4, A small angle of twist less than 5 degrees without any draping of the rod reduced the break- ing force by 13 pereent. A draping angle of 4 degrees, with a S-degree ngle of twist, reduced the breaking. force by 22 percent. The combined effect of a 7-degree draping angle and approximately S-degree angle of twist reduced the breaking force by 28 percent, PCI JOURNALTable 3. Effect of draping angle of CFCC 1 x7 (12.5 mm) prestressing tendons. {Deviator diameter D = 20.0 in, (508 mm) and tendon diameter d = 0.5 in. (12.5 mm), Dfd = 40; anchor type: resin filling-system with lock nut.) ‘Reduction in Draping angle ‘Breaking force ‘Average breaking force breaking force (degrees) Cashion Test number Kips (kN) ips () (percent) ° | L 36.8 (163.8) 368068) | oO 1 30.1 1339), 5 No 2 “| 345529) 322(1433) n 3 322434) 1 | eos) | 5 Yes 2 368 (164.1) 36.3 (161.5) 1 3 33.9(151.2) a L 24.4 (108.8) 10 No 2 249 2140218) 26 3 “RT(78) | aT 7 1 342 (1520) 10 Yes 2 345 (1537) 33514911) 9 3 318 (141.6) EXPERIMENTAL PROGRAM. CONDUCTED AT LTU Four prestressed concrete bridge models were constructed and tested under different loading, conditions. The first bridge model (DT-1) is a single double tee (DT) girder. Seven- wire twisted CFCC cables, provided by Tokyo Rope Manufacturing Incor- poration, were used in the internal and externally draped tendons. Glass fiber reinforced polymer (GFRP) rods ‘were used as reinforcing bars in the ‘webs, top flange and deck slab. Mild steel stirrups were used for shear ‘The second bridge model (DT-2) consisted of (wo DT girders. Leadline CFRP rods, provided by Mitsubishi Chemical Corporation (MCC), were used for internal tendons in the longi- tudinal and transverse directions and for reinforcing bars in the webs, top flange, and deck slab. The internal pre- stressing rods in the four webs were routed after post-tensioning while the transverse prestressing rods were not ¢grouted, Multiple Leadline rods within fone anchorhead were used for the ex- temally draped tendons on both sides of each web, Mild steel stirrups were used for shear reinforcement. The third model (DT-30) had a 30- degree skew angle and Leadline CFRP rods were used for internal prestress- ing in the longitudinal and transverse Soptomber-Ostober 1998 directions and for the externally draped tendons. All internal prestress- ing rods were grouted. Leadline CFRP rods were used for reinforcing bars. Closely spaced CFRP stirrups (4 in. (101.6 mm) apart), provided by MCC, were used. Fig. 3. Anchorage arrangement for CFRP Leadline prestressing rods. ‘The fourth bridge model (DT-15) had a 15-degree skew angle and con- sisted of three DT’ girders and five ceross-beams. Leadline CFRP rods and stirrups were used in the construction, similar to Model DT-30. The trans- verse prestressing rods were not Table 4. Effect of draping angle of CFRP (10 mm) Leadline prestressing rod, est conditions nee Draping angie Breaking force breaking force (degrees) Torsion ips (kN) (percent) ° No 483 215.0) ° ° Yes 42.2 (188.1) B 4 Yes | _37.6(167.2) 2 7 ne 36.4 (161.7) 25 7 Yes 348 1548) 28 aFie eS eae ‘SROSS-SECTION OF OT=15_routed, while all the longitudinal pre siressing rods were grouted. ‘The dimensions and details of the four bridge models are shown in Fig. 4, Table 5 shows the mechanical prop erties of CFCC and CFRP tendons as published by the manufacturers. The arrangement of the external prestress- ing tendons of the models is shown in Figs. Sa through Sd Construction Technique The bri in four phases: In Phase I, the DT girders were pre cast and internally prestressed. Pre: stressing the DT girders internally placed the entire cross section in com. pression, making them safer to trans. port to the testing area. After the gird ers were placed on their supports, grouting material was injected under pressure from one end of the girders to models were constructed the other, In Phase Il, 50 percent of the trans verse presiressing force was applied at the cross-beams and tendon deviators. This linked the DT girders trans versely without inducing a significant moment Table 5. Properties of CFCC and CFRP Leadline extemal prestressing tendons (published by the manufacturer Designation Nominal diameter, i, (mm) ‘Actual diameter, in. mm) Effective cross-sectional area sain, (om) Linear density 1bs per Fm) E si Nir) Tensile sreng Modilus of elastic, ksi Nim?) Elongation ‘Average breaking fore, Kips (&N) CRCC 1x7 (2.5 mm) CERP mm) 04925) 0315 (69) 05127) 0315 0) 0.12.06 071846.) 01 032) 00507) 3270.25) 326 (225) 20,500 (141) 21,300 (147) 16 percent TSpercent 31.9 (182) 23.4108) During Phase III, the deck slab was poured over the entire bridge. Note that the stirrups were extended from the DT girder webs, cross-beams, and tendon deviators into the deck slab in ‘order to ensure the transfer of horizon tal shear forces. Sikadur epoxy adhe- sive was sprayed on the top of the flange one hour prior to pouring the deck slab, Finally, in Phase IV the exter- nally draped tendons were post- tensioned and the remaining 50 per- cent of the transverse prestressing force was applied. Additional de- Fig, 5. External prestressing tendons of the four bridge models ‘Septomber-October 1998 tails of construction can be found in other literature.** PRESTRESS LOSSES Prestress losses 04 construction, due to st peated loads and due to holding con- stant deflection, are discussed. curring duri and re- Losses During Construction Two weeks after the deck slab was poured, the external CFCC tendons of Bridge Model DT-1 were post- tensioned, The anchored end of the sstendon was fitted with a load cell and an anchothead. A hydraulic jack was placed on the live end of the tendon. A. second anchorhead was placed on the second die-cast of the tendon after the jack. The tendon was pulled to the proper tension and the jack was r tracted. The second anchorhead was removed and the process was repeated for the next extemal tendon. The mea- sured elongation was verified as con- sistent with the jacking force. Polyethylene tubing was placed around the tendons at the tendon de ators to protect the tendons from wear and friction Tendons X-Ib and X-2a were post- tensioned first, achieving initial pre- stressing forces of 24.9 and 18.3 kips (110.8 and 81.4 KN), respectively. Tendons X-La and X-2b were post- tensioned 8 days later, achieving ini- tial prestressing forces of 17.5 and 18.1 kips (77.9 and 80.5 KN), respec tively. The responses of the external tendons of Bridge DT-1 during con- struction are shown in Fig. 6a. This Presbensng Foca (be) ‘Tine O2ys) (©) DT-20 5 120s Tie (Day) (9 DTS Fig. 6. Response of external prestressing tendons during construction. 98 PCI JOURNAL,‘graph indicates that the losses are in- significant and that the addition of the second two external tendons relieved some of the force carried by the first ‘hwo tendons. When the concrete strength of the deck slab of Bridge Model DT-2 reached approximately 7000 psi (48.3 MPa), the external [2 x 8 mm (0.079 x (0.315 in.)] Leadline rods were post- tensioned. The apparatus used was ar- ranged so that two rods would act as a single tendon in order to achieve the desired prestressing force. Once the tendons were positioned, monitoring and anchoring devices were con- nected. The load cells were placed next to the steel bearing plates. The anchorhead and a lock mut were placed ‘on the tendon after the load cell. Once the threaded steel rod and the jack were properly aligned, the jack pulled the tendons to the proper tension. After shimming, the jack was slowly retracted. The prestressing jack was then moved to the next tendon, The external tendons experienced ete at Se = — SS X48 3") soo 92300 sooo 7e00To000 ood (os) (prt (Dre 30004 a eee 2200 ttt a SS =x ae =e IS = is rr aa 10004 =e = mei =e =8 =~ =8 soo =e = = is = a “ob RO085 3800500009 ee te) ce (p30 (Drs Fig. 7. Response of external prestressing tendons during static load test. ‘September-October 1988 65some losses after the conclusion of construction. Fig. 6b shows the changes in prestressing force in the extemal tendons during construction. Itis apparent that the average loss was approximately 5 percent for all the tendons. This 5 percent change trans- lates into roughly 1800 Ibs (8.0 KN) of prestressing force lost out of approxi- rately 23 kips (102.4 kN) over a con- struction period of 120 days. As with Bridge Model DT-2, the ex ternal tendons in Bridge Models DT- 30 and DT-15 were post-tensioned in an alternating sequence, beginning from the center and progressing out- ward, left and right. This was to avoid stressing one side more than the other. Figs. 6c and 6d show the changes in prestressing forces of Bridge Models DT-30 and DT-15, respectively. The average prestressing loss in the central tendons of Bridge DT-30 (X-1b and X-4a) was approximately 6.2 percent, while the average percentage loss in the outer tendons (X-1a and X-4b) was approximately 13.4 percent. The (Dro Presresing Fores (ba) a i we 123 e 8 67 No.of Opts (nition) pra Fig. 8. Response of external prestressing tendons during repeated load test 96 PCI JOURNALprestressing tendons of Bridge Model DT-15 experienced similar losses. Losses due to Static Loading ‘A four-point loading was designed to simulate scaled-down HS-25 truck loads located over the midspan of Bridge Models DT-1 and DT-2. Loading was applied in 1000 Ib (4.45 KN) increments to $000 Ibs (35.6 KN). The external tendons experi- enced changes in their prestressing force due to the applied loading. These changes are shown in Fig. 7a. ‘The changes were insignificant, as the largest change occurred in Ten- don X-2a, which experienced a 309 Ib (1.38 KN) increase. Bridge Model DT-2 exhibited a lin- ear deflection response during the static load test. Fig. 7b shows the aver- age prestressing forces in the extemal tendons. It is clear that the tendons ex- perienced only small increases in pre- stressing force due to the 10 kip (44.5, KN) static load. In fact, the largest in- crease was only 0.8 percent, or 162 Ibs (721). An eight-point load was incremen- Ly applied normal to the deck of Bridge Models DT-30 and DT-15 at midspan, This eight-point loading was designed to simulate the load distribu- tion of two scaled down trucks located at the midspan of the bridge model. Loads were applied in 2 kip (8.9 KN) increments to 20 kips (88.0 KN). Fig. 7c shows the prestressing forces in the tendons under static loading for DT- 30. The changes in prestressing forces were insignificant. Bridge Model DT-15 was statically loaded to a point beyond its cracking ‘moment so that flexural cracks would develop in the DT webs at midspan. ‘The effect of repeated loading on the response of the cracked DT prestressed. section was then examined. Further- more, these cracks simulated an over- load condition during the lifespan of the bridge. Loads were applied in 10 kip (44.5 kN) inerements to 50 kips (222.5 KN). Fig. 7d shows the pre- stressing forces in the tendons under static loading. Again, changes in the prestressing forces were insignificant Losses due to Repeated Load A static set point load of 4 kips (17.8 KN) was placed on Bridge Model DT-1. The load was then sinu- soidally oscillated between 1 and 7 kips (4.45 and 31.2 KN) at a frequency ‘of 3.25 Hz for 7.0 million cycles. Pre- stressing forces were monitored regu- larly throughout the repeated loading test. Minor fluctuations in prestressing forces occurred during repeated load- ing, as shown in Fig. 8a. Aside from an initial drop during the first 100,000 cycles, these changes were minimal. The losses due to 7 million cycles of repeated loading were 2.45, 1.48, 2.78, and 2.72 percent for Tendons X-1a, X-Ib, X-2a, and X-2b, respectively. A static point load of about 7 kips (31.2 KN) was placed on Bridge Model DT-2. The load was then sinu- soidally applied between 2 and 11 kips (8.90 and 49.0 KN) at a frequency of 3.00 Hz for 7.0 million cycles. Under repeated loading, the external tendons of DT-2 experienced an average varia- tion in prestressing force of approxi- ately 150 Ibs (667.5 N). 2300 3% i I sao soto Days Fig. 9. Change in prestressing forces of DT-15 external tendons under 2 in. (50.8 mm) deflection at midspan. ‘September-October 1998 ow‘The lowest variation occurred in Tendon X-1a and was 105 Ibs (467.3 KN), while the highest variation was about 160 Ibs (712 kN) and occurred in Tendon X-Ib. Thus, it is evident that the variations in prestressing force due to cyclic loading are insignificant, as shown in Fig. 8b. Including the ini- tial drop in prestressing forces during the first 1 million eycles, the average Joss was about 3.9 percent. As with the two previous bridge models, a static point load of 7 kips G12 KN) was placed on Bridge Mod- els DT-30 and DT-15. The load was then sinusoidally oscillated between 2 and 14 kips (8.90 and 61.6 kN) at a frequency of 2.0 Hz for 7.0 million ey cles. Figs. 8c and 8d show the changes in prestressing forces in the external tendons of Bridge Models DT-30 and DT-15, respectively. The changes ‘were minimal, with the average loss in the prestressing force being approxi mately 4.3 and 5.4 percent for DT-30 and DT-15, respectively It should be pointed out that the re- peated load tests were conducted within the working load limit (less than the cracking load). As a result, the stress risers in the tendons are low. Therefore, an infinite fatigue life was anticipated in the four tested bridge models. Losses due to Holding Constant Deflection ‘A constant deflection test was con- ducted on Bridge Model DT-15 for 22 days before an ultimate load test. The 6 Fig, 10. DT-1 external prestressing tendons after complete failure. bridge model was loaded gradually until its midspan deflection reached 2 in. (50 mm), then a spacer frame was inserted between the bridge and the loading frame to prevent the bridge from returning to its initial po- sition. The prestressing forces were ‘monitored daily. 9 shows the variation of pre stressing forces over a period of days. Theoretical calculations predict that the tendon force should increase between 1.7 and 3.1 kips (7.5 and 13.8 KN). This is close to the difference be- tween Figs. 7 and 9, The 2 in. (50.8 mm) static deflection over a period of 22 days had no significant effect on the prestressing forces in the external tendons. PRESTRESSING FORCES UNDER ULTIMATE LOADING On completion of the repeated load- ing test, each bridge model was sub- jected to an ultimate load test, This as carried out in the same manner as the static loading test, with increased incremental loading until failure oc- curred. The data collected during the ultimate load test was used to det mine the relationship between the ap- plied load and the prestressing forces. None of the externally draped tendons ruptured during testing of the four bridge models, as shown in Fig. 10. Figs. Ia through 11d show the re- sponse of the prestressing forces in Bridge Models DT-1, DT-2, DT-30 and DT-15 due to the applied load. ‘The prestressing forces in the external tendons increased linearly up to the cracking load. Beyond that, the pre- siressing forces increased linearly, but with a different slope. This behavior can be attributed to changes in the conerete such as cracking and spalling. In all the tested models, the prestressing forces increased to about twice the inital prestressing values. Failure of the tested models initiated by crushing of concrete at midspan. DUCTILITY Each bridge model was subjected to loading and unloading cycles near its ultimate load-carrying capacity. This was done in order to separate the in- clastic absorbed energy (E,,) and elas tic stored energy (E.,.), and to deter- mine the energy ratio. The energy ratio is the ratio of the inelastic energy divided by the total energy (Eq) Bridge Mode! DT-1 experienced only fone major flexural crack at midspan. This crack started at about 9 kips (40 KN) and grew deeper and wider as the load approached the ultimate load ca- pacity of the model, Failure was initi- ated by crushing of concrete followed by rupture in one of the intemal CFCC tendons, None of the externally draped tendons experienced failure. ‘The residual deflection after unload- ig was found to be 0.5 in, (12.5 mm). he unloading path was not recorded and was assumed to follow a straight line connecting the deflection at maxi- ‘mum load and the residual deflection. The energy ratio of DT-1 was about 41 percent (see Fig. 12a), indicating that its ductility was about half the ductility of a girder made of conven- tional materials, Bridge Model DT-2 experienced considerable flexural cracking before failure. The spacing between the cracks was similar to the spacing be tween the stirrups. As the testing load was increased, the crack widths in- creased and more cracks developed. Significant spalling occurred at the ‘ks. Failure was initiated by con- crete crushing at the top slab and flange, immediately followed by rup- ‘ure in the internal prestressing CFRP rods. Neither the transverse tendons PCI JOURNAL,nor the externally draped tendons ex- perienced rupture, The unloading paths have been recorded and are shown in Fig. 12b The inelastic energy was calculated ‘based on an average area of the un- loading path. The energy ratio was about 62 percent, which is about 88 percent of that of a prestressed con- crete girder made from conventional materials (see Fig. 12) ‘The additional inelastic energy is defined as the energy experienced when the deflection increases with no increase in the loading. This energy, shown in Fig. 125, was a result of the combination of bonded internal ten. dons in the longitudinal direction, un- bonded internal tendons in the trans- verse direction and externally draped tendons. The increase in the energy ratio indicates a considerable increase in the ductility of the bridge. AAs in Bridge Model DT-2, a consi 8 Rano” 20000 Prostrocsng Foros (be) (a) DT 7900 Tao) 22800 Presbessing Foc (bs) ()DT-30 "000 600032000 Fig, 11 Response of external prestressing tendons during ultimate load test ‘September-October 1998Energy Ratio= 41% B= 429 kipin Eye 176 kipin : ‘Applied Load (Ibs) @ prt Energy Ratio = 54% Applied Load (ibs) o2 4 6 8 Deflection (in) (@pr20 10 12 0123456789 6 8 0 2 i Deflection (in) &DT2 Energy Ratio = 4% E.°789kipin Deflection (in) Fig. 12. Energy ratios of the four tested bridge models, erable amount of cracking with spalling was observed during the ulti- mate loading test of Bridge Model DT-30. However, less deflection was experienced at failure of DT-30 in comparison to the deflection experi- enced by the DT-2 bridge model. ‘The failure mechanism for Bridge Model DT-30 was the same as that for DT-2. This failure was initiated by the compression failure of con erete. In this case, the conerete in the deck slab reached the maximum con- crete compressive strain, allowing for the experienced additional inelastic energy. The energy ratio of DT-30 ‘was about 54 percent, which is ap- proximately 12 percent less than the 100 ratio experienced by DT-2 (see Fig. 12c). This can be attributed to smaller amount of additional inelastic energy absorbed near ultimate load, As in Bridge Models DT-2 and DT- 30, Bridge Model DT-15 was loaded and unloaded until failure took place. Flexural cracks were seattered be- tween the tendon deviators, At about 90 percent of the ultimate load-carry- ing capacity, the CFRP prestressing tendon in the cross-beam located at midspan, directly under the load, ex- perienced rupture. The model was unloaded and reloaded again, and near the ultimate load the top deck slab experienced con- crete crushing. At that point, a sudden drop in loading was noted. The load was increased again and the midspan ccross-beam failed, followed by rupture in the internal longitudinal prestressing tendons. The energy ratio was about 54 percent, as shown in Fig. 12d In comparing the energy ratios of the four bridge models, it appears that the highest energy ratio can be achieved if the longitudinal internal tendons are bonded and the trans- verse internal tendons are not. Obvi ously, the externally draped tendons were a common factor among all four tested girders and played a major role in forcing the concrete to undergo inelastic deformation result- ing in compression failure. PCI JOURNALCONCLUSIONS Based on the test results obtained from this experimental study, the fol- owing conclusions can be drawn: 1. Successful results can be ob- tained using CFCCICERP tendons in prestressed concrete bridges by com- bining bonded internal tendons with unbonded extemally draped tendons. 2. The strength of CFCC/CERP ten- dons is adversely affected by the mag- nitude of the draping angle as well as, the deviator diameter. Reducing the draping angle, increasing the deviator diameter, and cushioning the tendon at the devialor minimize the reduction in the tendon breaking force. 3. Losses in the prestressing force in externally draped tendons are ex- pected to be within 5 to 7 percent. In- significant losses (about 3 percent) are anticipated due to repeated loads. Furthermore, no damage (or distress) is observed due to the application of 7 million cyctes of repeated loads, if the repeated loads are within the working load limit (below the con- crete cracking load) of the bridge. 4. A sustained load causing a deflec- tion of 2 in, (50.8 mm) for 22 days has an insignificant effect on the prestress- ing forces. 5. Externally draped tendons help t0 increase the “energy ratio” and allow a larger deflection under ultimate loads. ‘The increase in the energy ratio is the result of forcing the bridge models to fail by crushing of concrete rather than by rupture of the internal prestressing tendons. This type of failure allows the concrete to undergo inelastic de- formation so that additional inelastic energy is experienced 6. Externally draped tendons are un- likely to experience rupture under ulti- mate loading conditions. RECOMMENDATIONS In order to fully utilize the advan- tages of CFCC/CFRP tendons in pre- stressed concrete bridges, and to avoid the shortcomings of their mechanical characteristics, the following design recommendations are made: 1. Cushioning materials should be used between the tendons and the de- viators. The corners of the deviators must be rounded to a diameter of at least 20 in, (508 mm). If these two conditions are met, the draping angle can be as large as 10 degrees without an appreciable reduction in the strength of the tendons. 2. The attachment of two die-casts at one end of a CFCC tendon should bbe avoided. This eliminates the poten- tial reduction in the tendon breaking force. 3. Biforts should be made to avoid twisting the tendons during post- tensioning. However, designers should allow @ 10 percent reduction in tendon strength to accommodate the negative effects of twisting that may occur. 4, Designers should combine inter- nally bonded tendons with externally raped tendons to ensure better duct ity and to force the structure to fail by REFERENCES crushing of concrete rather than by rupture of the internal tendons. 5. Designers may allow for a long- term total loss in the prestressing force of approximately 10 percent, which includes the effect of repeated traffic loads. This is only true if similar me- chanical anchoring systems are used for the externally draped tendons and the traffic loads are below the concrete cracking load. ACKNOWLEDGMENT ‘This research project was funded by the National Science Foundation under grant numbers CMS-9640570, CMS-9540657, and CMS-9401211 ‘The support of Dr. J. Scalzi, Program Director of Large Structural Building Systems, is greatly appreciated. Funds provided by the Concrete Research Council of the American Conerete In- stitute and the Michigan Department of Transportation are gratefully ac- knowledged. ‘The construction of Bridge Model DT-1 was made possible through the efforts of T. Enomoto and T. Tsuchiya at Tokyo Rope Manufacturing, Inc. The support of T. Hoshijima, T. Mizuno, K. Yagi, and C. Ballinger of Mitsubishi Chemical Corporation for the construction of Bridge Models DT-2, DT-30, and DT-15 is greatly appreciated. Some results presented and dis- cussed in this paper were obtained from Tokyo Rope Manufacturing and Mitsubishi Chemical Corporation |. Rao, P. S.. and Mathew, G., “Behavior of Externally Prestressed Concrete Beams with Multiple Deviators,” ACI Structural Jour- ral, V.93, No. 4, July-August 1996, pp. 387-396. 2.Manabe, H., Kanaumi, S., Inoue, S., and Miyagawa, T., “The Ultimate Strength of PC Segmental T-Girders Using an FRP Ex- ermal Prestressing System,” Proceedings of Third Symposium (on Fiber Reinforced Plastic Reinforcement for Concrete Struc tures, Sapporo, Japan, V. 2, October 1997, pp. 791-798. 3. Saeki, N., Horiguchi, K., Inomata, M., Hata, S., and Tkeda, T., “Strengthening of Damaged Concrete Beams by External Pre- stressing of Aramid Fiber Cable,” Proceedings of First Sympo- sium on Fiber Reinforced Plastic Reinforcement for Conerete Structures, ACI SP-138, Detroit, MI, April 1993, pp. 913-932, 4. Burgoyne, C. J., “Rational Use of Advanced Composites in Concrete,” Proceedings of the Third International Symposium con Non-Metallic (FRP) Reinforcement for Concrete Structures, Sapporo, Japan, V. 1, October 1997, pp. 77-88 ‘Soptombor-October 1998 5.Grace, N. F., and Abdel-Sayed, G., “Double Tee and CFRPIGERP Bridge System,” Concrete International, V. 18, No. 2, February 1996, pp. 39-44, 6.Grace, N.F., and Abdel-Sayed, G., “Feasibility of CFRP/GFRP Prestressed Concrete Demonstration Bridge in the USA.” Fourth National Workshop on Bridge Research in Progress, National Center for Earthquake Engineering Research, Buffalo, NY, 1996. 7.Grace, N. F., and Abdel-Sayed, G., “Ductility of Prestressed Concrete Bridges Using CFRP Tendons,” Concrete Interna- tional, V. 20, No. 6, June 1998, pp. 25-30. 8. Grace, N. F., and AbdelSayed G., “Behavior of Externally/in- temally Prestressed Concrete Composite Bridge System,” Pro- ‘ceedings of Third International Symposium on Non-Metallic (ERP) Reinforcement for Concrete Structures, Sapporo, Japan, V. 2, October 1997, pp. 671-678. 101