Product Testing And Physical Properties Contents
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comProduct Testing and Physical PropertiesContentsProduct Testing and Physical Properties . 11.0.Complete Test Plan. 12.0.Product Validation . 32.1.Longitudinal Tensile Strength and Modulus, ASTM D7205 . 32.2.Bond Properties (in concrete), ASTM D944 or ACI 440.3R B.3, completed by GeorgeMorcous, Ph.D., P.E., University of Nebraska-Lincoln . 42.3.Shear Strength, ASTM D7617. 62.4.Interlaminar Shear Testing after Alkaline Exposure . 72.5.Accelerated testing for alkali resistance, Completed by Brahim Benmokrane,Ph.D.,P.E., Universitie de Sherbrook . 82.6.Durability Properties, ACI 440.3R-12 B.6. 102.7.Creep Resistance . 112.8.Fatigue Performance . 142.9.Glass Transition Temperature . 142.10.Moisture Absorption . 142.11.SEM Analysis. 152.12.Bond Dependent Coefficient . 161.0. COMPLETE TEST PLANNeuvokas manufactures basalt fiber reinforced polymer (BFRP) reinforcing bar for use inreinforced concrete construction, using a patented, modified, high speed pultrusionprocess (HSRP). Neuvokas has identified specific testing based on the American ConcreteInstitute (ACI) 440.3R-12, Guide Test Methods for Fiber Reinforced Polymer (FRP)Composites for Reinforcing or Strengthening Concrete and Masonry Structures. Thisdocument lays out an extensive list of test procedures that can be necessary to completedepending on final application of the FRP product. The general strategy developed byNeuvokas is to initially focus on a select group of primary tests. These primary tests wereNeuvokas Corp.Page 1
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comselected by a Professional Civil Engineer as being critical for slab-on-grade and the tilt-upwall concrete markets. These tests are listed below.1.2.3.4.Longitudinal Tensile Strength and Modulus, ASTM D7205Bond Properties (in concrete), ASTM D944Shear Strength, ASTM D7617Interlaminar Shear testing with alkaline resistance, ASTM D4475Each of these tests has been completed and has allowed Neuvokas to establishperformance when compared to competitors’ (GFRP and BFRP) published performancedata. Table 1 shows the complete list of completed vs in-process testing.Neuvokas has continued to evaluate product performance specific to the use of its productin structural design. These applications may require additional test information thatNeuvokas has not fully completed at this time, but is in process and nearly complete.These tests are listed below. Certain tests listed below have extensive time requirementsand these specifics tests have been identified and begun.1. Creep Properties, ASTM D7337 (To complete creep testing lower load levels canrequire up to 1 year to complete) In-process, begun August 20162. Durability Properties, ACI 440.3R-12 B.6, (on-going test)3. Fatigue Properties, D3479, Completed, working on data comparison4. Bond Dependent Coefficient CompletedIn addition to product performance testing Neuvokas has completed the following materialcharacterization tests.1.2.3.4.5.6.Coefficient of thermal expansion, ASTM E831Glass transition temperature, ASTM E1356Moisture Absorption (on-going test)Volume Fraction, ASTM D3171Alkaline Resistance of FiberComparative SEM AnalysisNeuvokas Corp.Page 2
SpecificationPrimaryTestingLongitutal Tensile Strength and ModulusBond PropertiesShear StrengthInterlaminar Shear TestingASTM D7205ACI 440.3R-12 B.3ASTM D7617SecondaryTestingCreep PropertiesDurability PropertiesFatigue PropertiesBond Dependent CoefficientASTM D7337ACI 440.3R-12 B.6ASTM D3479OtherMaterialPropertiesCoefficient of Thermal ExpansionGlass Transition TemperatureMoisture AbsorptionVolume FractionAlkaline Resistance of FiberComparative SEM AnalysisASTM E831ASTM E1356ComTest ProcedureInProcesspletedPO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comxxxxxxASTM D3171xxxxxxxxxTable 1. Chart of completed vs. in process Neuvokas BFRP rebar testsNeuvokas uses a combination of certain tests mentioned above to monitor the quality of rebarthat is produced. Tensile testing, shear testing, moisture absorption, resin percentages, and fibersizing content are all tests that are used to ensure a high quality product is being produced. Testssuch as glass transition temperature are completed periodically to ensure these material propertyvalues do not change.2.0. PRODUCT VALIDATION2.1. LONGITUDINAL TENSILE STRENGTH AND MODULUS, ASTM D7205Tensile testing is completed per ASTM D7205 specifications. Figure 1 contains an image ofa rebar sample loaded in a mechanical test frame and a failed sample after testing. ACI440.6-08, Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials forConcrete Reinforcement, has requirements for the tensile strength of rebar products.Neuvokas basalt rebar will meet or exceed the requirements for glass FRP rebar in allcases. This ACI documents lists the required strength for glass FRP rebar, #3 size, at 110ksi.Neuvokas Corp.Page 3
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 1. Tensile sample tested to failure in test lab at Michigan Tech UniversityThe industry standard for calculating a tensile strength that can be published as aguaranteed tensile strength is to subtract three times the standard deviation from theaverage strength. Neuvokas has tested over 150 samples and does testing weekly toensure a quality product is being manufactured. It can be seen in Table 2 that Neuvokashas a guaranteed tensile strength of 145.6 ksi based on the latest data available. It can alsobe seen in Table 2 the average elastic modulus (Young’s Modulus) is approximately 6000ksi. This also meets the ACI specifications for glass FRP rebar.#3 GatorBar Tensile StrengthAverage Max Load17966.4 lbsAverage Max Stress162.8 ksiStandard Deviation5.7 ksiAvg. -3stdev145.6 ksiAverage Modulus6061.8 ksiTable 2.#3 Gatorbar Tensile Strength Summary This data is representative of basalt fibersmanufacturing into 3/8” diameter rebar via the HSRP process .2.2. BOND PROPERTIES (IN CONCRETE), ASTM D944 OR ACI 440.3R B.3, COMPLETED BY GEORGEMORCOUS, PH.D., P.E., UNIVERSITY OF NEBRASKA-LINCOLNAs part of the product development process Neuvokas has evaluated multiple coatings onrebar. Concrete pullout testing was conducted per the procedure described in ACI 440.3R12 B.3.Neuvokas Corp.Page 4
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comTypically there are three methods that the FRP industry uses to bond concrete to rebar.These include surface deformations, externally wound fibers, or a secondary sand coating.Neuvokas has produced multiple coatings both with a secondary process and an inline,primary process. Concrete pull-out testing was used as a direct A vs. B comparison ofthese coatings.To complete this test the University of Nebraska was contracted. Dr. George Morcous hascompleted this testing on other manufacturers FRP rebar products. To complete this testthe ACI procedure is followed and rebar is cast into 8” x 8” x 8” blocks of concrete. Figure 2shows a Neuvokas rebar sample loaded into a tensile testing machine prior to testing.Figure 2. Neuvokas rebar sample loaded in Tinius Olson Universal Testing MachineResults from this testing can be seen in Table 3. As mentioned in previous paragraph theprimary coating is applied “in-line” and this results in a lower product cost. As can be seenin Table 3 the secondary coating does have higher pullout values, but the performance ofthe primary coating is still sufficient when compared to steel rebar at a typical 1400 psi.The average bond stress using this loading is 2,047 psi for primary coating, and 3,753 psifor secondary coating. Neuvokas continues to utilize concrete pullout testing to comparecoatings.Neuvokas Corp.Page 5
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comTable 3. Results from second run of concrete pull-out testing, completed by GeorgeMorcous, Ph.D., P.E., University of Nebraska -LincolnNeuvokas will be continuing additional concrete bond property testing that will compare theprimary sand coating to the bond of steel rebar directly. While this concrete bond test has beendeveloped to understand the rebar bond to concrete the various variables involved require adirect A vs. B comparison. This testing will be completed within Q2 of 2017.2.3. SHEAR STRENGTH, ASTM D7617Shear testing shows Neuvokas material has consistent test-to-test results and test resultsfalling within the range of published industry standards for FRP rebar. In-fact as Table 4shows Neuvokas GatorBar has slightly higher shear strength than other industrycompetitors. The values in Table 4 are guaranteed values that have been calculated usingthe same method as discussed in the tensile section of this report (Total Average – 3 *Standard Deviation). The industry standard that ACI 440.6-4 requires is 18 ksi. See Table 4and Figure 3.Guaranteed ValuesShear Load Shear StrengthlbsksiNeuvokas #3 Bar5,60225.3Hughes Brothers Aslan 1004,40022V-rod Standard5,50025Table 4. Shear test results compared with competitorsNeuvokas Corp.Page 6
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 3. Shear test fixture and tested samples2.4. INTERLAMINAR SHEAR TESTING AFTER ALKALINE EXPOSUREA test that was completed by Neuvokas to address the effect of alkalinity on rebar wasinterlaminar shear (aka short beam test). This test is designed to look at interfacedegradation and is done per ASTM D4475. As can be seen in Figures 4 and 5 there was noeffect on the epoxy matrix based on SEM image analysis. Table 6 shows the interlaminarshear strength before and after conditioning. Again, the alkalinity seems to have had noeffect on interface degradation of Gatorbar.Figure 4. Cross section view rebar after interlaminar shear before conditioningNeuvokas Corp.Page 7
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 5. Cross section view of rebar after interlaminar shear after conditioningTable 6. Interlaminar shear strength, before and after conditioningWhen considering rebar durability alkaline resistance is still the primary concern. Based onthe testing completed Neuvokas basalt rebar will not be affected by alkalinity. The finaltest that will be completed will evaluate the tensile strength after alkaline exposure.2.5. ACCELERATED TESTING FOR ALKALI RESISTANCE, COMPLETED BY BRAHIM BENMOKRANE,PH.D.,P.E., UNIVERSITIE DE SHERBROOKAlkaline resistance (aka durability testing) has been used as a standardized test by the ACIduring the development of glass fiber products. Glass fiber is susceptible to degradationwhen exposed to alkaline environments. Over the course of glass fiber productdevelopment this has led to unique sizing materials that are placed on the fiber to improvethe resistance to alkalinity. These products are sold as ECR or boron modified fiber insteadof the standard E-glass. A key difference between basalt fiber and glass fiber is that basaltis inherently more resistant to alkalinity. Neuvokas has received basalt fibers from multipleNeuvokas Corp.Page 8
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comsuppliers and the performance of each fiber was tested in multiple solutions following atest procedure that was published by Owens Corning in 2011 for evaluating glass fiberchemical resistance. As can be seen in Table 7 the first lot 1 of the China basalt showedslightly higher weight loss after exposure to alkaline solutions. However, the weight lossseen for all fibers was not significant.Fiber Lot Deionized Water Alkaline Solution Acidic Solution Saline Solution10.23.25.10.120.12.13.7030.124.60Table 7. Effect of various solutions on basalt fiber (% weight loss)The images below were taken with a scanning election microscope and show the conditionof basalt fiber both before and after conditioning with the various solutions. Images weretaken by the Universitie de Sherbrooke in Sherbrooke Quebec.Figure 7. SEM images of A) Reference B) Deionized Water C) Alkaline Solution D) Acidic Solution E)Saline SolutionNeuvokas Corp.Page 9
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.com2.6. DURABILITY PROPERTIES, ACI 440.3R-12 B.6The final alkalinity exposure testing that has been mostly completed requires exposingproduct to elevated pH and temperature. Samples are then tested via ASTM D7205 tensiletesting to measure the effect of the alkalinity on performance. This testing is not designedto determine a long-term expected rebar life, but to simply understand how alkalinity willaffect performance. Minimum values for this testing have not been established via theindustry at this point, but Neuvokas has done comparisons to published data fromcompetitors such as Hughes Brothers.BaselineAfter 30 dayPercent LossexposureAverage Max Load, lbs18,20014,11022.5%Average Max Stress, ksiStandard Deviation, ksiAvg.-3stdev, ksi1643.6153.1127.91.8122.422.0%N/A20.0%Average Modulus, ksi5964.659510.2%Table 9. Effect of alkalinity after 30 days with Neuvokas GatorbarIt can be seen in Table 9 that Neuvokas rebar had approximately 20% loss in tensilestrength after 30 days of exposure during this test. Earlier it was discussed how Neuvokasrebar had no loss in inter-laminar shear strength after alkalinity exposure. Inter-laminarshear evaluates the interface between resin and fiber where the tensile testing evaluates adifferent material property of the resin system.To further investigate the cause of tensile strength losses after durability testing Neuvokashas completed water only and temperature only testing. It was discovered that after 30days of only elevated water exposure that the loss in tensile strength was similar to that ofelevated high alkalinity water. Based on these results water absorption is the primaryfactor degrading the epoxy matrix and this is responsible for the loss in tensile properties.Neuvokas Corp.Page 10
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 9. Effect of elevated temperature and elevated temperature water on tensile strengthafter 30 days2.7. CREEP RESISTANCEAccording to the ACI 440-.1R-10 FRP reinforcing bars that are subjected to a constant load overtime can suddenly fail. This is often called the endurance limit for these types of products.Unfortunately there is not a lot of data available on the failure or performance of FRP reinforcingusing this test and Neuvokas wanted to determine if current assumptions from the ACI wereappropriate for GatorBar.Michigan Tech built two test stands for creep testing and will build more once initial testing iscompleted. These frames are designed to accommodate up to 20,000 lbs of tensile load on therebar samples. The first sample was loaded on February 8, 2016? with a load of 10,477 lbs. Thetest evaluates the creep performance so samples are loaded and the machine will measure thetotal hours until failure.Neuvokas Corp.Page 11
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 10. Neuvokas BFRP loaded into creep test frame with 10,477 lb loa d on rebar.Results from Neuvokas BFRP can be seen Figure 12. This data shows results between 1 hour and6,500? HOW DO WE GET THIS? hours of data with the corresponding load values. A reportcompleted by the University of North Florida titled Degradation Assessment of Internal FiberReinforcement in Concrete Environment discusses the typical issues with Creep and Relaxationperformance of FRP rebars. This report offers that there is a linear relationship between creeprupture strength and the logarithm of time for all load levels. Based on the extrapolation of shortterm creep data this means that longer service lifetimes suggest that typical glass FRP rebarsshould have rupture strengths of 29-55% of ultimate tensile strength over X YEARS.Neuvokas Corp.Page 12
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 11. Neuvokas BFRP failed during creep testingFigure 12. Neuvokas creep dataUsing the data that be seen in Figure 12 Neuvokas and Michigan Tech will be completing moretesting that will allow a linear equation to be obtained from this data. Once this is complete anestimated creep design value for a 50 year life will be obtained.Neuvokas Corp.Page 13
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.com2.8. FATIGUE PERFORMANCEFatigue testing is also being completed at Michigan Tech using a hydraulically operated tensile setup. This setup cycles rebar at 4 hz. The cycles to failure are recorded and plotted on a fatigue lifecurve. This test began in January 2017 and it is not complete yet. Neuvokas will be performingmore testing at each load seen below to determine variability in the results.Past studies by El-Ragaby et al. (2007) have shown GFRP-reinforced concrete bridge deckspecimens had better fatigue performance and longer fatigue life than steel-reinforcementconcrete bridge decks. Data shown below will be compared to other GFRP rebar products, butbased on the similar modulus of elasticity between BFRP and GFRP it is expected that this dataperformance trend will remain consistent.Figure 11. Chart showing the number of cycles to failure at multiple loads2.9. GLASS TRANSITION TEMPERATURENeuvokas has measured its glass transition temperature of its resin per ASTM E1356 to be225 F. ACI 440.6-3 has established a minimum value of 212 F.2.10. MOISTURE ABSORPTIONMoisture absorption is used as a method to determine the quantity of voids present in theFRP product. As previously discussed this is likely the most important factor in surabilityconsiderations. The CSA has established a maximum value of .75% and the ACI hasestablished a maximum value of 1%. This is evaluated using ASTM D570 with a watertemperature of 122 F.Neuvokas Corp.Page 14
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comNeuvokas is using this to evaluate each lot of rebar produced on its manufacturing line foracceptance.Figure 13. Snapshot of Gatorbar moisture absorption, showing .75% maximum value by the CSA.2.11. SEM ANALYSISNeuvokas uses SEM images to determine fiber wet-out and volume fraction of eachcomponent. Figure 11 shows a cross-section of the Neuvokas rebar and is used todetermine gross fiber wet out percent. Volume fraction of fiber, resin, and voids is alsoused with great accuracy by using image analysis tools. Neuvokas has also utilized theseimages for competitive analysis within the FRP industry for benchmarking purposes andinitial results have been extremely promising.Figure 14. Neuvokas rebar sample at two magnificationsNeuvokas Corp.Page 15
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comCompetitive SEM analysis was also completed and can be seen in Figure 12 and 13.Samples from major competitors were set up and analyzed via SEM. Figure 13 shows thateach of these competitors does have porosityFigure 15. Competitive samples of FRP rebar mounted for SEM analysisFigure 16. SEM images of competing glass fiber FRP rebar products. Starting from top le ft, AslanFRP, FireP, and V-rod2.12. BOND DEPENDENT COEFFICIENTBond dependent coefficient accounts for the amount of bond between FRP rebar and theconcrete it is embedded in. For FRP rebar having the same bond to concrete as steel the value isdefined as being 1.0 with less than 1.0 being better than steel and greater than 1.0 being worsethan steel. The ACI 440.1R document recommends using a conservative value of 1.4 when otherspecific test data is not available.Bond dependent coefficient testing was completed by the University of Nebraska. This test is setup as a four point bend test with two point loading. Figure 17 shows the dimensions of the beamand the test setup and Figure 18 shows a basalt FRP rebar beam during testing. Figure 19 showsNeuvokas Corp.Page 16
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comthe specifications for reinforcement in each beam. It can be seen here where the placement ofthe reinforcement being studied is placed.Figure 17. Beam and test set-up dimensionsFigure 18. Basalt FRP reinforced beam during testingNeuvokas Corp.Page 17
PO Box 220 Ahmeek, MI 49901 Phone: (906)934-2661 Fax: (906)934-2662 info@neuvokascorp.comFigure 19. Reinforcement specifications for each beamThe results from this testing are shown in Table 10. The values in this table are used in theequation from ACI 440.1R-06 to calculate the bond dependent coefficient, kb. The standardproduct offered by Neuvokas is the Surfaced BFRP in Table 10. This #3 rebar product had a kbvalue of 0.80 and since this is lower than 1.0 it means better performance than its steelcounterpart.Table 10. Results from bond dependent coefficient testingNeuvokas Corp.Page 18
440.6-08, Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials for Concrete Reinforcement, has requirements for the tensile strength of rebar products. Neuvokas basalt rebar will meet or exceed the requirements for glass FRP rebar in all cases. This ACI documents lists the required strength for glass FRP rebar, #3 size, at 110
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