STRENGTHENING OF CORRODED STEEL STRUCTURES

USING CFRP – AN EXPERIMENTAL REVIEW

Ghada M. El-Mahdy(i), Abdallah H. Yassin(ii), Abd El Rahman Khaled(iii)

(i) Professor, Faculty of Engineering, The British University in Egypt (BUE), Egypt
(ii) Civil/Structural Engineer, Arab Contractors, Egypt
(iii) Civil/Structural Engineer, Private Office, Egypt

ABSTRACT

Fibre reinforced polymers (FRP) have been widely used to strengthen

reinforced concrete structures, however, nowadays their use to strengthen steel
structures is under investigation. In particular, the need to strengthen corroded
steel structures found in aggressive environments, such as marine
environments, which have undergone a reduction in cross-sectional area and
hence a reduction in their load-carrying capacity is in need of studying. The
main problems that arise when using carbon fibre reinforced polymer (CFRP)
sheets to strengthen steel structures is the weakness in the interfacial bond
between the CFRP and the steel surface, the thinness of CFRP sheet, and the
possibility of the occurrence of galvanic corrosion between the carbon fibres
and the steel surface. To study these factors an experimental program was
undertaken to determine the performance and efficiency of using CFRP to
strengthen steel structures. In these experiments beam specimens were tested
to see if the FRP caused a notable increase in their flexural capacity. The tests
included both corroded and un-corroded steel beam specimens in the
unreinforced state and reinforced by CFRP, as well as specimens with an
insulating layer of glass fibres to help prevent galvanic corrosion. The results of
the beam tests suggested that the thickness of the CFRP sheet is an important
parameter and that a good bond resistance is required as this was the main
failure mode.

KEYWORDS: beam tests, CFRP, corrosion, galvanic corrosion, glass fibres,

steel structures, strengthening.

INTRODUCTION

Steel structures can undergo corrosion especially when exposed to aggressive

environments such as marine environments. This corrosion causes the outer
surface of the steel to react electrochemically to form oxides, which are flaky
and friable in nature and disintegrate the surface layers of the steel. This
causes a reduction in the cross section of the steel elements reducing their
load-carrying capacity. Hence, corroded steel structures need strengthening to
compensate for their loss in load-carrying capacity. Welding steel plates onto
the corroded section have traditionally done this strengthening. However, in
many circumstances such as in offshore petrochemical plants using a live flame
to weld steel sheets onto deteriorated sections is not a feasible solution due to
the risk of starting a fire (Teng et al. 2012), and so alternative methods of
strengthening steel structures need to be implemented.
Fibre reinforced polymers (FRP) have been successfully used to
strengthen concrete structures (Hollaway and Teng, 2008; Hollaway, 2004; Wu
and Eamon, 2017; Spadea et al., 2015; Eid and Paultre, 2017; Belarbi and
Acun, 2013; Zhang et al., 2017; Attari et al., 2012) and so extending their
application to strengthen steel structures is an attractive alternative. FRPs are
applied using a suitable adhesive to the element to be strengthened and so no
risk of fires will occur as with the use of welding. Previous research has shown
that FRP strengthening of steel structures is feasible (Karbhari, 2014; Rizkalla
et al., 2008; Sen et al., 2001; Miller et al. 2001; Zhao and Zhang, 2007; Uddin,
2013). However, the bond between the steel and the FRP is the most critical
factor (Smith and Teng, 2001; Stratford and Cadei, 2006; Al-Emrani and Kliger,
2006; Benachour et al., 2008; Wu et al., 2012; Chiew et al., 2011; Yu et al.,
2011; Yu et al., 2012). Due to the thin nature of FRP sheets and the high
strength of steel, for any strengthening to be effective, more than one layer of
the FRP sheet will need to be used requiring a very effective bond resistance.
When using carbon fibre reinforced polymers (CFRP) to strengthen a steel
structure (Deng and Lee, 2007; Linghoff et al., 2009; Fam et al., 2009; Linghoff
et al., 2010) the possibility of galvanic corrosion occurring between the carbon
fibres and steel should be addressed (Tavakkolisadeh and Saadatmanesh,
2001; Hollaway and Cadei, 2002; Schnerch et al., 2006). Galvanic corrosion is
an electrochemical process in which one metal (steel) corrodes when it is in
electrical contact with another (carbon), in the presence of an electrolyte. This
galvanic reaction is exploited in batteries to generate a useful electrical voltage
to power portable devices; however, it is undesirable in the situation of using
carbon fibres to strengthen steel in aggressive environments. Therefore, the
use of an insulating layer of possibly glass fibres to prevent this reaction is
advisable (Photiou et al., 2006).
In this research, an experimental program was conducted to test the
effectiveness of strengthening corroded steel structures using CFRP. First the
tensile properties of the steel beams were determined using tension tests, and
then the bond strength of the adhesive was determined using a double lap joint
test specimen. Finally, beam tests were conducted for both un-corroded and
corroded specimens reinforced on the lower tension flange using CFRP alone
and using CFRP with an insulating layer of glass fibres.
The objective of this study is to make recommendations on the use of FRP
materials and adhesives locally available in Egypt to strengthen steel structures.
Attention is given to the thickness of FRP plates needed to strengthen steel
beams efficiently. This research has significant implications on the marine oil
and gas industry where strengthening corroded steel members with FRP can
save timely interruptions to production needed to replace these members and
the risk of starting a fire during the welding of steel plates.

EXPERIMENTAL PROGRAM

1- Materials Used
In this experimental program, materials locally available in Egypt were
used. A 6 m IPE80 steel bar, purchased from a local supplier, and cut into
beams of 1 m length was used for the experimentation. The IPE80 section has
a depth of 80 mm, a flange width of 46 mm, a web thickness of 3.8 mm, and a
flange thickness of 5.2 mm. This section was used as it is the smallest IPE
section available and hence would not need a high capacity testing machine.

(a) (b) (c)

Fig. 1: (a) CFRP plate, (b) adhesive mortar, and (c) fiberglass mesh

The CFRP used was Sika Carbodur S512 plates, which had a thickness of
1.2 mm and a width of 50 mm giving a cross-sectional area of 60 mm2, shown in
Fig. 1(a). Sika Carbodur plates are pultruded carbon fibre reinforced polymer
(CFRP) laminates designed for strengthening concrete, timber, and masonry
structures. The tensile modulus of elasticity, ECFRP, of Sika Carbodur S
products is 165 GPa and the mean laminate tensile strength is 3.1 GPa
determined according to ASTM D3039/D3039M-14 (Sika, 2017; ASTM, 2014).
The adhesive used to bond this CFRP to the steel sections was Sikadur-30LP,
which is a solvent-free, thixotropic, epoxy-based two component adhesive
mortar (Sika, 2016). In this adhesive Component A and Component B are
mixed in proportions of 3:1 to form a grey coloured mortar, shown in Fig. 1(b).
The glass fibres used as an insulating layer between the steel and CFRP was a
product known as crack tape produced by CMB Egypt, which is a self-sticking
fiberglass mesh tape used for joints and wall repair, shown in Fig. 1(c). This
fiberglass mesh had a width of 50 mm.
 2- Tension Tests
Standard tension tests were conducted to identify the mechanical
properties of the steel sections. Two tensile coupons following the
specifications of ASTM E8/E8M-16a (ASTM, 2016) were laser cut from the web
of one of the beams and tested in a SUNPOC WDW-100D universal testing
machine, as shown in Fig. 2(a). The strain was measured using an
extensometer with a gauge length of 50 mm. The average properties obtained
from the two tension tests were modulus of elasticity Est = 203 GPa, yield stress
Fy = 384 MPa, and ultimate tensile strength Fu = 556 MPa. These values were
used to calculate the theoretical yield moment My, plastic moment Mp and
deflection  of the beam tests.

(a) (b)
Fig. 2: (a) Tension coupon in testing machine, and (b) Stress-strain curve
of tension test 1

3- Bond Test
The bond between the CFRP and the steel is the most critical factor in using
CFRP to strengthen steel structures because de-bonding of the CFRP is the
most likely cause of failure of this type of strengthening. For CFRP
strengthened steel structures interfacial failure cannot occur in the steel as it
does in concrete structures due to the much higher tensile stress of the steel
than that of the adhesive (Teng and Fernando, 2012). Referring to Fig. 3, for
steel structures the modes of debonding failure are cohesion failure within the
adhesive layer or adhesion failure, either between the steel and adhesive or
between the CFRP and adhesive. Possible failure modes that can occur in the
CFRP are rupture of the CFRP perpendicular to the fibres or interlaminar failure
of the CFRP parallel to the fibres, as shown in Fig. 3.
 CFRP rupture
Interlaminar failure of CFRP

CFRP

Adhesion failure at CFRP/adhesive interface

Adhesive
Cohesion failure in adhesive
Adhesion failure at steel/adhesive interface
Steel

Fig. 3: Failure modes of a steel/CFRP joint (Teng and Fernando, 2012)

To investigate the bond behaviour between the steel and CFRP a bond test
was performed. To enable the use of the universal testing machine for the bond
test, a double-lap splice specimen was prepared as shown in Fig. 4, which
could be axially aligned between the two grips of the testing machine as shown
in Fig. 5(a). The bond test specified in ASTM D7616/D7616M-11(2017) (ASTM,
2017), which is a single-lap shear splice specimen was not used as the
eccentricity in the specimen could not be facilitated in the testing machine.

2 CFRP Plates 230x50x1.2 mm 2 Steel Plates 180x46x3.8 mm

Adhesive

Fig. 4: Double-lap splice bond test specimen

The double-lap splice specimen consisted of two steel plates cut from the
web of the IPE80 sections having dimensions of 180 x 46 x 3.8 mm connected
using two plates of CFRP having dimensions of 230 x 50 x 1.2 mm. The
surface of the two steel plates was prepared by mechanical abrasion of the
oxidized layer using sand paper which induced scratches in the steel surface to
enhance mechanical bonding. After this pre-treatment, the surfaces of the two
steel plates as well as the surface of the CFRP were cleaned with a chemical
solvent (acetone) to remove any traces of dirt or contaminants to leave both
surfaces chemically active and able to chemically bond with the adhesive layer.
The components of the Sikadur-30LP adhesives were mixed and applied to the
steel and CFRP plates and left to harden.

(a) (b)
Fig. 5: (a) Bond test specimen in testing machine, and (b) failure mode of
bond test specimen

The two steel plates were inserted into the grips of the universal testing
machine and a tensile test was conducted to find the shear resistance of
adhesive, as shown in Fig. 5(a). A little initial slipping occurred in the testing
machine’s grips then the specimen was loaded till a load of 44.2 kN after which
the de-bonding failure in the adhesive accompanied by longitudinal interlaminar
failure of the CFRP occurred as shown in Fig. 5(b). The shear resistance of the
adhesive was calculated by dividing the load by twice, to account for double
shear, the area of the adhesive which was 115 x 46 mm. The shear stress –
slip relationship is plotted in Fig. 6. This plot shows that the relationship of the
shear stress to the slip of the adhesive is linear till failure having an average
value of 1.06 MPa/mm.
 Fig. 6: Shear stress-slip relationship obtained from bond test

4- Beam Tests
Beam tests were conducted on un-corroded and corroded beam
specimens in both the un-strengthened and strengthened state to determine the
efficiency of strengthening corroded steel structures using CFRP. As the
testing machine available for the tests could only facilitate beam specimens of
50 cm length, the 1.0 m long IPE sections were all cut in half. This allowed a
beam to be placed in the testing machine with a clear span of 40 cm as shown
in Fig. 7. The beam specimens were loaded at mid-span. Initial attempts to
prevent the occurrence of web crippling during the tests by using a loading plate
failed as this required a load of greater than 100 kN to reach the maximum
flexural capacity of the un-strengthened beam which was greater than the
capacity of the testing machine. So, the beam specimens were tested without
the loading plate which induced significant deformations in the upper flange and
web because of the concentrated load.
Seven beam specimens were tested in this experimental program as
outlined in Table 1. The first specimen, B1, was considered the control
specimen and consisted of a steel beam IPE80 section in its original state, un-
corroded and unreinforced. This specimen was used to compare the capacities
of the other specimens. The second specimen, B2, was a corroded beam that
had been immersed in a solution of hydrochloric acid (HCl) for three days till a
considerable amount of corrosion had taken place on the surface of the beam.
This specimen was unreinforced and was used to determine the decrease in
flexural capacity due to the corrosion. The third specimen, B3, was an un-
corroded beam with the underside of the bottom flange of the central part of the
beam reinforced using the 1.2 mm thick CFRP plate having a length of 25 cm
as shown in Fig. 8(a). In underside of the bottom flange of this specimen was
prepared in a similar manner to that used for the bond tests to ensure the same
bonding conditions. The fourth specimen, B4, was like specimen B3 but a
corroded beam was used to test the efficiency of the strengthening on corroded
beams. The surface of the bottom flange was prepared by mechanical abrasion
using sand paper and chemically cleaned using the solvent. The fifth specimen,
B5, was used initially to determine the effect of placing an insulating layer of
glass fibres between the steel and CFRP, but also acted in showing the effect of
using a thicker layer of FRP reinforcement. This specimen was of un-corroded
steel and had three layers of glass fibre mesh having a length of 25 cm placed
in the central part of the underside of the bottom flange as well as a sheet of 1.2
mm thick CFRP also having a length of 25 cm. The underside of the bottom
flange was prepared before applying the adhesive and a layer of adhesive was
applied between each layer of glass fibre mesh and CFRP. The sixth
specimen, B6, was like specimen B5 but a corroded steel beam was used.
Finally, the seventh specimen, B7, was made of an un-corroded steel beam
with a 1.2 mm sheet of CFRP having a length of 50 cm bonded to the underside
of the bottom flange such that the supports acted to prevent the occurrence of
de-bonding failure between the steel and CFRP, as shown in Fig. 8(b).

40 cm

Fig. 7: Set-up of beam tests

Each specimen was placed in the testing machine and the load piston was
lowered till it touched the top flange of the beam. The load was set at zero then
applied gradually measuring the load and displacement of the piston to obtain
load-deflection curves.
 Table 1: Details of beam test specimens
Specimen Length of
Corrosion CFRP GFRP
No. CFRP
B1 (Control) No No No -
B2 Yes No No -
B3 No Yes No 25 cm
B4 Yes Yes No 25 cm
B5 No Yes Yes 25 cm
B6 Yes Yes Yes 25 cm
B7 No Yes No 50 cm

Load Load
IPE80 IPE80

CFRP 25 cm CFRP
adhesive
40 cm 40 cm
50 cm CFRP 50 cm
(a) (b)

Fig. 8: (a) Beam specimen B3, and (b) beam specimen B7

RESULTS AND DISCUSSION

Table 2 shows the failure loads of the seven beam specimens. It can be
seen from the results of B1 and B2 that the corrosion process achieved by
submerging the beams in HCl for three days caused a notable degradation in
the unreinforced corroded beam. The results showed an 8.8% loss in section
capacity. This is also demonstrated in Fig. 9, where the corroded beam showed
a lower load-carrying capacity and decreased ductility. Figure 9 also shows the
theoretical load-deflection curve for a beam loaded at midspan by a
concentrated load (PL3/(48EI)). The significant difference between the
theoretical deflections and the experimental deflections was due to the
occurrence of web crippling under the concentrated loads. As the deflection
that was measured was that of the loading piston, the experimental deflections
were excessive with regards to theoretical flexural deflections.
 Table 2. Experimental failure loads of beams
Specimen No. Failure Load (kN)
B1 86.9
B2 79.3
B3 86.9
B4 76.0
B5 91.0
B6 81.3
B7 89.2

100
90
80
70
Load (kN)

60
50
40
30 Control Specimen - B1
20 Corroded Specimen - B2
10 Theoretical deflection
0
0 5 10 15 20 25
Deformation (mm)
Fig. 9: Load-deformation curves for unreinforced beams B1 & B2

Fig. 10: Beam test of specimen B1 showing web crippling at the

concentrated load
 The specimens that were reinforced with 25 cm of CFRP in the midspan
region of the beam, specimens B3 and B4, did not show a significant increase
in load-carrying capacity, as can be seen in Fig. 11 for the un-corroded and
corroded beams. In fact, for the corroded specimen a reduction in load-carrying
capacity was observed for specimen B4, which could be possible due to a
varying degree of corrosion than specimen B2. Also, Fig. 11 shows that the
specimens that were reinforced with CFRP showed less ductility than the
reinforced specimen due to an increase in their rigidity. Considerable peeling of
the CFRP occurred in these specimens before the final failure of the beam, as
can be seen by Fig. 12.

100
90
80
70
Load (kN)

60
50
40 Control Specimen - B1
30 Corroded Specimen - B2
20 CFRP Reinforced - B3
10 Corroded CFRP Reinforced - B4
0
0 5 10 15 20 25
Deformation (mm)
Fig. 11: Load-deformation curves of specimens with CFRP reinforcement,
B3 and B4

Fig. 12: Significant debonding of the CFRP

To see if preventing premature debonding of the CFRP would make a
difference in the results, specimen B7 was compared to specimen B3, as shown
by the load-deformation curves in Fig.13. Specimen B7 showed a small
increase in load-carrying capacity of 2.3 kN (2.6%), which demonstrates that
preventing debonding has a small effect, however, this was at the expense of
the reduced ductility of B7 compared to B1.

100
90
80
70
Load (kN)

60
50
40 Control Specimen - B1
30 CFRP Reinforced - B3
20
10 Full Length CFRP Reinforcement - B7
0
0 5 10 15 20 25
Deformation (mm)
Fig. 13: Load-deformation curves of specimen with full length
reinforcement (i.e., no peeling)

100
90
80
70
Load (kN)

60
50
40 Control Specimen - B1
30 Corroded Specimen - B2
20 CFRP/GFRP Reinforced - B5
10 Corroded CFRP/GFRP Reinforced - B6
0
0 5 10 15 20 25
Deformation (mm)
Fig. 14: Load-deformation curves of specimens reinforced with both CFRP
and GFRP, specimens B5 and B6
 The GFRP fabric was initially intended to prevent the occurrence of
galvanic corrosion, however, in the scope of these tests it served to show that
increasing the number of layers of FRP had a significant effect on the load-
carrying capacity, 4.1% for B5 and 2.5% for B6. However, as can be seen from
Fig. 14, even this effect was obliterated with the occurrence of debonding of the
FRP which reduced the load to that of the originally unreinforced beam.

CONCLUSIONS

An experimental program was conducted to investigate the potential of

using FRP to reinforce steel beams, and in particular corroded steel beams.
The results showed that one layer of FRP has an insignificant effect on the steel
beam, and several layers are needed to contribute to the load-carrying capacity
of the beam. The results also showed that premature debonding was a major
issue with the use of FRP to reinforce steel beams, which needs to be
addressed properly. It is recommended that some sort of mechanical anchors
be used to increase the efficiency of the FRP. It is also recommended that
several layers of FRP be used with the addition of mechanical anchors. In this
way, there is a chance that this method of strengthening steel structures could
succeed.

ACKNOWLEDGEMENTS

The authors would like to acknowledge CMB Egypt for donating the glass
fiber crack tape. Thanks, are also due to the British University in Egypt (BUE)
for the use of the Materials Testing Laboratory.

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