FIBERGLASS REBAR - Oregon.gov

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FIBERGLASS REBARand OregonDOTPrimary reinforcing in BridgesJonathan Fischer P.E.Fiberglass Rebar Engineer/Business DevelopmentOwens Corning Infrastructure SolutionsCell: 308-999-0858jonathan.fischer@owenscorning.comNote: Owens Corning is not responsible for authentication of information obtained from open source

OWENS CORNINGWE BUILD MARKET LEADING BUSINESSES – GLOBAL IN SCOPE, HUMAN IN SCALECOMPANY FINANCIALSCOMPANY HISTORY2019 CompositesBusiness Revenues:66193819,000COUNTRIES WHERE WEEMPLOYEESOPERATECONSECUTIVE YEARSAS A FORTUNE 500COMPANY2019 REVENUEMARKET LEADING BUSINESSESROOFINGINSULATION 2 billionPRODUCT OFFERINGCOMPOSITESPINKBAR Fiberglas RebarOwens CorningMATEENBAR Fiberglas Rebar and Dowels

OWENS CORNING COMPOSITESBUSINESS UNIT World-leading producer of glass-fiber and glassfiber composites Serves diverse customers in the building andconstruction, transportation, wind energy,consumer and industrial markets across the globe Composite materials are found in more than70,000 end-use applications Owens Corning composite products deliverproductivity and performance benefitso Enhanced durabilityo Design flexibilityo Light-weightingo Corrosion Resistance3

OWENS CORNING INFRASTRUCTURESOLUTIONS, LLC Subsidiary of Owens CorningComposites Acquisition of Hughes Brothers in2017 MATEENBAR Fiberglas Rebarmanufacturing facility in Concord, NC Involved in manufacturing, distributing,and educating users on FiberglassRebar Vertically integrated with glass fibermanufacturing to provide end-to-endsupport Experienced engineers on team toprovide technical support4

WHAT ISFIBERGLASSREBAR?Fiberglass rebar is a compositematerial made of two nonmetallic components and isused for concrete reinforcing. Fiber - Structural Element E-CR Glass Matrix - Binder Vinyl Ester Epoxy Polyester (NOT ASTMD7957 compliant)5

HOW FIBERGLASS REBAR IS MADEGFRP RebarForm FactorsASTM D7957 lays out material specifications6

WHY AND WHERE SHOULD FIBERGLASSREBAR BE USED? Concrete structures susceptible to corrosion:oSteel corrosion by chlorides / saltsoAggressive agents that lower concrete PhoSlender structures with minimum coverconcrete Concrete structures requiring non-ferrousreinforcement due to:oElectro-magnetic considerationsoThermal non-conductivity Where machinery will “consume” the reinforcedconcrete member (i.e., mining and tunneling) In low demand slab applications, where laborsavings can result in project savings while alsoproviding a longer lasting element7

KEY BENEFITS COMPAREDTO TRADITIONAL REBAR Extended Service Life Improved Durability No Corrosion means no spalling/concretedegradation Ease of Installation Higher Tensile Strength No need for expensive overlays or admixtures Labor Savings Lightweight – 1/4th of steel Upwards of 50% reduction of man hours Improved Working Conditions Transparent to magnetic fields Electrically & thermally non-conductive More Stable Pricing8

CONCRETE REINFORCEMENT MARKET SEGMENTSEach segment involves specific opportunities for steel rebar replacementHigher LoadDemandHeavy- Lower LoadLoadDemandStructural Structure failure has riskfor human lives Under Codes & StandardsResidential/LightCommercial Structure failure has no risk for human lives May be under Codes & Standards (depends on country) Building skeletons (incl. foundation) Bridges Piles Tunnel segments Soft-eyes (temporary) Sea walls Dowel bars Industrial floors Tram slabs Rail plinths House foundations Basement walls Wall/façade panels Commercial floors Parking and driveways (flatwork) Roads Precast architectural elements Canals Temperature & shrinkage reinforcement9

FIBERGLASS REINFORCEMENT SOLUTIONS – MULTIPLE PRODUCTSConcrete ReinforcementCIVIL / HEAVY CONSTRUCTION20 YEARS ASTM D7957 Fiberglass Rebar Durable, economic concretereinforcement solutions vs. corrosionresistant steel reinforcementOwens Corning MATEENBAR Fiberglas RebarOwens Corning Fiberglas Dowel BarsRESIDENTIAL / LIGHT COMMERCIALBridge DecksSea WallsJointed PavingCrack Mitigation for Slab on Ground Economic solution for crack mitigationvs. black steel in slab-on-groundapplications Residential Walls and Footings PINKBAR Fiberglas RebarAgricultural PadsDrivewaysIndustrial Pads10Owens Corning purchased Hughes Brothers in 2017. OC has been a major supplier of continuous filament glass fibers to the fiberglass rebar industry for 20 years.”

DRY DOCK REHABILITATION PEARL HARBORMARINE & WATERFRONT APPLICATIONS11

MAUI HONOAPIILANI HIGHWAY – ORIGINALLY BUILT IN 2001MAUI NEW HONOAPIILANI HIGHWAYMORE MARINE & WATERFRONTAPPLICATIONS12

2.4 MILES OF ELEVATED RAILHEAVY RAIL – MIAMI METRORAIL13

FIBERGLASS DOWEL BARS APPLICATIONS Used as shear load transferdevices Ideal for: Jointed ConcretePavements Toll loops Corrosion resistant Electromagnetically neutral Smooth surface naturallyde-bonds from concrete No need for grease No need for sleeves No need to seal ends Fiberglass rebar used astie-barsNote: Fiberglass dowel bars may be used with steel or plastic chairs14

PORT OF ROTTERDAM, HOLLAND15

BRIDGE APPLICATIONS In the USA 100 installations by OwensCorning where Fiberglas bars are used inbridge decks or other bridge components.ACMA maintains a comprehensive list of N.American bridge projects. At least 25 states have used fiberglassbars in their DOT bridge structuresoTexas, Florida, Ohio, Colorado, Minnesota,Iowa, Idaho, Missouri, and Utah to name afew Maine alone constructed double digitbridges in 2019 Recently included in both the Oregon DOTand Washington DOT bridge designmanuals16

Penobscot Bridge Route 155/6,Emma Park Bridge,I635 over State Ave,Howland/Enfield Maine DOT, 2016Helper Utah DOT, 2009Kansas City Kansas DOT, 2013SUCCESSFUL BRIDGE PROJECTS17

VALIDATION IN THE FORM STATE SPECIFIC STANDARDS TxDOT has a standardalternative plan in bidpackages for FiberglassRebar reinforced Decks Florida DOT has standardsin place for barrier wallprofiles and bent shapes Ohio DOT has a repeatablebarrier wall standard forFiberglass Rebar18

WASHINGTON - STATE SPECIFICATION New addition to the state’s Bridge Design Manual First project (Satus Creek) due for install in August 2021* Document Source: WSDOT Bridge Design Manual. July 2019 Version19

OREGON - STATE SPECIFICATION Allowance for Fiberglass Rebar versus Stainless Steel in Coastal Areas* Document Source: Oregon Department of Transportation. Bridge Design Manual, October 2019 version.20

CODES, STANDARDSAND GUIDELINES

PRODUCT AND DESIGN STANDARDS ASTM, AASHTO-BDS AND ACI ASTM D7957-17 defines materialspecifications Design of GFRP-RC bridge elementsfollows structure of Bridge Design Specifications for steel-RC/PC (AASHTOBDS-17, 8th Ed.). Same language and integration Familiar environment for the practitioner ACI 440.1R-15 Design with FRP rebars ACI 440.5-08 Construction with FRPrebars22

SIGNIFICANT MILESTONEHarmonizeUpdateExpand23

EXPAND PROVISIONS TO INCLUDE ALL MEMBERS OF A BRIDGEBent CapPiles300mm12''mm30012''FootingsSpirals #3t8#8Concrete Cover 1.5''24

MATERIAL AND TESTING STANDARDS ASTM D7957 Lays out material specifications and testingmethodology Currently specifies Mean Tensile Modulus ofElasticity of 44.8GPa Benefits of ASTM Establishes baseline quality Competitive bidding CSA S807 Lays out material specifications and testingmethodology FDOT 932.2 Example of state specific standard; Florida Lays out the state’s own: Testing methodology Sourcing/production certification25

MATERIAL CERTIFICATIONSAlways Demand an ASTM D7957Compliant Product!26

.DESIGN – FIBERGLASS REBAR VERSUS STEEL Fiberglass Rebar design done using ACI 440.1R or the AASHTOLRFD Design Guide for Fiberglass Rebar Documents follow the same design process and steps as steel.Differences going to be primarily driven by different environmentalfactors/multipliers or material propertiesSame straightforward design approach as with steel Fiberglass Rebar is Linear Elastic Continues to add stress at a linear rate to failure No Yield Point, not ductile End State Failure Mode:f Steel – Yielding of Reinforcement Fiberglass Rebar – Concrete Crushing (desired mode; 0.75) Bar Rupture (0.55) Warning signs present: Large deformability (significant deflectionor crack widths) are visible indicators of pending failure. Design examples present in ACI440.1R Appendix for referenceCompressionControlledFailure byFRPrupturerf b1.4rf brf27

DESIGN – MATERIAL PROPERTIES COMPARISON AND CONSIDERATIONSPropertyFiberglass RebarSteelTensile StrengthUpwards of 145KsiStandard 60ksi (Grade 60)Modulus of Elasticity8,700,000 psi29,000,000 psiBondKb (Bond Coefficient) .80 to .95Kb 1.0Transverse ShearUpwards of 26ksiApproximately 36ksi (60% of Fy)Weight0.287 lb/ft for #5 Fiberglass1.000 lb/ft for #5 Steel Less clear cover needed Potential for more efficient designs or use of less concreteHowever, higher radial CTE for Fiberglass Rebar dictates a minimum of 2 bar diameters of clear No issues with “Dissimilar Metals” Fiberglass Rebar is compatible with steel lineupAllows for mixing of materials and hybrid designs Lap Splicing and Development Lengths similar (dependent upon design capacity) Fiberglass Rebar performs well in fatigue, but is susceptible to creep in regions with large sustained loads Due to low Modulus of Elasticity, serviceability issues such as deflections and crack widths typically governs the28Fiberglass Rebar layout

DESIGN MATERIAL PROPERTIES Strengthwhere:*f C ffuEfuCE is an environmental reduction factoro ffu is the design tensile strength of FRP, psio ffu* is the guaranteed tensile strengtho (ffu* fu,ave – 3s), psi

DESIGNING FOR SERVICABILITY Serviceability Crack Widths Deflection Creep Ruptureffæ s ö22W 2bkb dc ç è 2øEf(ACI 8-9)N.A.h1h2b h2h1kb 1.4dcbff reinforcement stresss bar spacingEf elastic modulus of the FRP reinforcements

31COST CASE STUDIESPATHS TO USAGE

32ANTHONY WAYNE TRAILBRIDGEPID No. 23593 LUC-25-7.92/8.29/8.37GFRP Bridge Deck Case Study, Mannik & Smith

ANTHONY WAYNE TRAIL BRIDGE, TOLEDO, OH Full replacement of the existing single spanstructure to three span (65’-100’-65’) Steel beam superstructure on semi-integralabutments and cap and column piers with crashwalls 98’ wide roadway with 10’ path and 6’ walk withinterior and exterior crash barriers33

DESIGN CONSIDERATIONSDesign DifferencesEpoxy Coated Steel#5 @ 6” Transverse Overall the deck design procedure stays largelythe same with only minor changes Other than design learning curve, the actualdesign process requires similar man hours tocomplete No changes necessary to concrete profileDetailing Differences 50% more reinforcing (by area) required using2009 AASHTO guidelines (new methodologymore efficient)GFRP Reinforcing#5 @ 4” Transverse Presently cannot use mechanical connectors, aclosure pour must be utilized for stageconstruction34

INSTALLED COST COMPARED TO EPOXY COATED STEELBridge Deck Rebar Installed Cost12010080105100Total Bridge Deck Job Cost BreakdownReinforcingMaterialsEPOXY COATED STEEL REBARFIBERGLASS REBARLabor213760844063200Epoxy Coated Steel RebarFiberglass RebarODOT PID No. 23593 LUC-25-7 .92/8.29/8.37 GFRP BridgeDeck Case Study, Mannik & 4Waterproofing5Waterproofing5Total Deck Cost100Total Deck Cost102TOTAL DECK COST IMPACT OF APPROXIMATELY 1% BASED ON ACTUAL BID RESULTSBridge deck figures based on calculations using the unit strip design method per AASHTO 2018 on the Anthony Wayne Trial bridge deck comparing Aslan 100 FiberglassRebar vs epoxy coated steel rebar, yielding savings of 5% total delivered cost favorable to Aslan 100; aligns with Mannik & Smith AWT cost analysis35

DESIGN & MATERIALCOST IMPLICATIONS COMPARED TO EPOXY COATED STEELDECK REINFORCEMENT MATERIALSEPOXY COATED STEEL REBARFIBERGLASS REBARCOST / LF 0.56 0.52COST/SQFT 4.35 5.79TOP LONGITUDINAL BARS#4 BARS @ 9.50” SPACING#4 BARS @ 8.00” SPACINGBOTTOM LONGITUDINAL BARS#5 BARS @ 8.00” SPACING#5 BARS @ 6.50” SPACINGTRANSVERSE BARS (TOP & BOTTOM)#5 BARS @ 6.00” SPACING#5 BARS @ 4.50” SPACING(1) #6 BAR(2) #5 BARS442.20602.07100133ADDITIONAL BARS OVER PIERSREBAR VOLUME (CUBIC INCHES)TOTAL MATERIAL COST36%ODOT PID No. 23593 LUC-25-7 .92/8.29/8.37 GFRP BridgeDeck Case Study, Mannik & SmithMore reinforcement volume33%higher material costsBridge deck figures based on calculations using the unit strip design method per AASHTO 2018 on the Anthony Wayne Trial bridge deck comparing Aslan 100 Fiberglass Rebarwith epoxy coated steel rebar, yielding savings of 5% total delivered cost favorable to Aslan 100; aligns with Mannik & Smith AWT cost analysis36

INSTALLATION IMPLICATIONS COMPARED TO EPOXY COATEDSTEELDECK REINFORCEMENT INSTALLATIONEPOXY COATED STEEL REBARFIBERGLASS REBARREBAR WEIGHT / LF1.040.28REBAR WEIGHT / SQFT1.580.51TOTAL REBAR BY WEIGHT (TONS)21.807.038728 2.60 1.6410060INSTALLATION TO LAY REBAR (HOURS)COST / SQFTTOTAL INSTALLATION COST68%less weight1/3of the time to lay rebar40%labor savingsODOT PID No. 23593 LUC-25-7 .92/8.29/8.37 GFRP BridgeDeck Case Study, Mannik & SmithBridge deck figures based on calculations using the unit strip design method per AASHTO 2018 on the Anthony Wayne Trial bridge deck comparing Aslan 100 (#5) Fiberglass Rebar with (#5)epoxy coated steel rebar; Installation assumptions: using #5 rebar as average sized bar diameter; 20’ length bars as standard length, installation time based on 4 hours to lay 1 ton of rebarbased on Foundation Steel estimates37

WHERE INDUSTRY IS HEADED WITH NEXT GENERATION PRODUCTGEN II FIBERGLASS MODULUS IMPROVEMENTModulus of elasticity increases from 6.5msi to 8.7msiReduced material usage with higher modulusReduced material yields incremental labor savings38

I-475 BRIDGE – OHIO – TOTAL COSTCOMPARISON39

I-475 OVER DORR ST. & HILL AVE. – OHIOEPOXY COATED STEEL REBARFIBERGLASS REBAR(2018 EDITION)PERCENT CHANGE(VOLUME)Transverse Bars#5 Bars @ 5.00”#6 Bars @ 5.00” 50.3%Top Longitudinal Bars#4 Bars @ 8.00”#4 Bars @ 6.50” 27.4%Bottom Longitudinal Bars#5 Bars @ 6.00”#5 Bars @ 5.00” 32.0% 10.104 10.025ParityCost Per Square Foot of Deck EPOXY COATED STEELREINFORCINGBridge Widening and Rehabilitation Twin structures Three-Span (52’ 73’-6” 52’) SteelBeam Composite Superstructure onSemi-Integral Abutments with Capand Column Piers60’ wide roadwayBeam spacing of 8’-0”FIBERGLASS REINFORCINGCost information is from Engineer’s estimate, Price of epoxy reinforcing @ 1.15/LB, Recent increase in steel cost (15%-20% Increase) Result in more competitive costs, Mechanical connectors 20/bar(Assumed); installation cost were based on Anthony Wayne Trail Bridge bid estimates40

HENRY COUNTY BRIDGE – OHIO – TOTAL COST COMPARISON41

INDUSTRIAL DRIVE BRIDGE – HENRY COUNTRY – OHIOEPOXY COATED STEEL REBARFIBERGLASS REBAR(AASHTO 2ND EDITION)PERCENTCHANGE(VOLUME)Transverse Bars#5 Bars @ 6.00”#6 Bars @ 5.00” 75.8%Top Longitudinal Bars#4 Bars @ 9.25”#4 Bars @ 6.25” 45.8%Bottom Longitudinal Bars#5 Bars @ 6.50”#5 Bars @ 5.00” 32.8%Additional Bars over Pier2-#5 Bars b/w Top Long.1-#5 Bar b/w Bot. Long.1-#6 Bar b/w Top Long.1-#6 Bar b/w Bot. Long. 42.5% 11.805 10.60910% SavingsCost Per Square Foot of Deck EPOXY COATED STEELREINFORCINGConstruction of new bridge across the MaumeeRiver Eight (8) Span (115’-7”) CompositePrestressed I-Beam Superstructure onReinforced Concrete Abutments with Capand Column Piers28’ wide roadway with 6’ raised sidewalkBeam Spacing of 10’-0” to 11’-7”FIBERGLASS REINFORCINGCost information is from Engineer’s estimate; Price of epoxy reinforcing @ 1.15/LB; Recent increase in steel cost (15%-20% Increase) Result in more competitive costs; installation costwere based on Anthony Wayne Trail Bridge bid estimates42

43PROVENDURABILITY

COLLABORATORS44

CORE SAMPLESTAKEN FROM 11 BRIDGE LOCATIONSSierrita de la Cruz Bridge, Amarillo TX -2000Salem Ave Bridge, Dayton OH - 199853rd Ave Bridge, Bettendorf IA - 2001Cuyahoga County, Ohio - 2002O’Fallon Park Bridge, Kittredge CO- 2002Gills Creek Bridge, Franklin County VA- 2003McKinleyville Bridge, Brooke CO WV - 1996Roger's Creek US460 – Bourbon CO, KY - 1997Thayer Rd Bridge – Newton Co, IN - 2004Walker Ave Box Culvert, Rolla MO - 1999Southview Bridge , Rolla MO - 200445

TESTING PROCESS Concrete cores extracted from bridges. Cores photographed and measured for sampleinventory. Testing matrix determined. Cores split and GFRP rebar extracted. GFRP tests performed. Concrete tests performed.46

SEM IMAGES Virtually no negativelyaffected fibers observed oninterior or exterior of inservice rebar. The fewnegatively affected fibersappear to have physicaldamage from specimenpreparation as they are nearresin voids. Extrapolateddamage was not visible inthis sample.Virtually no fibersnegatively affected byconcrete observed.47

ENERGY DISPERSIVE X-RAY SPECTROSCOPY (EDS)EDS does NOT suggest any evidence ofchemical attack in the GFRP bar.“Durability of GFRP Reinforcement in Built Structures: a 15 year old Concrete Bridge Deck. Gooranorimi, Bradberry, Nanni ASCE Journal Composites for Construction 2017, 21(5): 0401702448

Negligible evidence of fiberglass rebar being negatively affected by concreteenvironment after 15 years in service.OBSERVATIONS Today’s industry products are better than 10 years ago and perform better inaccelerated aging protocols Demonstrable confidence in long term durability justifies less conservativelimits in design guides. Characterization testing per ASTM D7705 for 90 days in a high pH durabilitybath to simulate 100 year service life. Retention of greater than 80% of tensileproperties.49

HOW DO I INSTALL, HANDLE, ANDSOURCE FIBERGLASS REBAR?A CONTRACTORS GUIDE

WORKMAN LIFTING REBAR51

Same bar sizes as steel: #2 to #13SIZES ANDAVAILABILITY Stock lengths include 20’ and 40’ bar Material delivered in wrappedbundles according to size and length Sold on a Linear Foot basis versus aprice per pound52

PREFABRICATED BENT BARS Bent bars available for bar sizes #2 to #8 Stock shapes and made-to-order available Bent bars arrive palletized or crated Manufacturer / Supplier able to assist inconverting a steel list to fiberglass alternative Bars unable to be bent on site. Work with thesupplier to ensure that the proper shapes andquantities are ordered.53

HANDLING The bars are very similar to steel, but significantlylighter. #5 Fiberglass .287 lb/ft #5 Steel 1.0 lb/ft Allows workers to carry more bars per trip, or useless workers to carry similar quantities Placement becomes easier due to ease ofhandling. While creating bent shapes on site is notpossible, field forming of straight bars to match aprofile is acceptable. The increased bar flexibility makes formingto curves a simple process on site. Recommended to wear gloves, as well as anyother project/site specific safety gear that isrequired Material will not get as HOT as steel can in directsunlightACI 440.5-08 CONSTRUCTION WITH FRP REBARS54

CUTTING Cutting Fiberglass Rebar will NOT compromise the bar’s durability. NO treatment or sealing of ends is necessary. Softer material results in easier and faster cutting No metal means less sparking and heat generation during cuttingTo cut, please use: Fine toothed saw on fieldDiamond tipped blade ina chop saw used in factoryDo NOT: Shear Bend and Break Torch55

TYING Plastic clips Zip ties PVC coated wire Epoxy coated wire Standard steel wire Tie guns Recommended that chairs beplaced more frequently forstability. 2/3 of normal chair Spacingmay be scoped on project.56

STORAGE Fiberglas Rebar is durable in the outdoorenvironment. Discoloration, fading or chalking of thesurface can occur due to oxidation or UVexposure. However, these effects are cosmetic onlyand will not impact the performance Recommended that if extended outdoorexposure is possible, that the bars shouldremain in their packaging or be tarped57

SOURCING This is a multi-source material, aligning withthe needs of a public bid system. Projects will continue to use steel bars. Anoption is working with your steel supplier ora distributor, allowing you to obtain onenumber for the entire reinforcementpackage. Direct Pricing and assistance available onsome projects. Owens Corning maintains both national andregional distributors of materials.58

59

Questions?THE PINK PANTHER & 1964–2021 Metro-Goldwyn-Mayer Studios Inc. All Rights Reserved

THE PINK PANTHER & 1964–2018 Metro-Goldwyn-Mayer Studios Inc. All Rights Reserved. 2018 Owens Corning. All Rights Reserved.Jonathan Fischer P.E.Fiberglass Rebar Engineer/Business DevelopmentOwens Corning Infrastructure SolutionsCell: 308-999-0858jonathan.fischer@owenscorning.com

Fiberglass Rebar is Linear Elastic Continues to add stress at a linear rate to failure No Yield Point, not ductile End State Failure Mode: Steel -Yielding of Reinforcement Fiberglass Rebar -Concrete Crushing (desired mode; 0.75) Bar Rupture (0.55) Warning signs present: Large deformability (significant deflection

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