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Development of curved non-ferrous reinforcement for reinforced concrete applications

Dev. Of materials, methodology, manufacturing process and design guidelines for a low-cost curved frp rebar to overcome limitations of current concrete reinforcement materials such as corrosiveness and inability to build curved parts.

This 2 year ¿1 project brings together a highly complementary team of 9 SMEs and 2 Universities from 6 EUREKA members to address the development of curved non-ferrous rebar for reinforced concrete applications. Steel has proven over many years to be a very suitable reinforcement for concrete. However, in situations where the service environment is particularly severe, the corrosion of steel rebars has become the most significant factor in limiting the life expectancy of reinforced concrete structures in Europe. The annual cost of repair and maintenance of the European infrastructure as a result of problems associated with corrosion is over ¿30B, and the repair costs can be twice as high as the original build. Reinforcing materials such as galvanised, expoxy coated or stainless steel rebars all suffer from limited effectiveness in specific high chlorine environments or prohibitive costs. Non-ferrous reinforcement (NFR), in the form of fibre reinforced plastic (FRP) rebars, has been developed in an attempt to combat these problems. Whilst FRP rebars have been shown to be very successful in the reinforcement of concrete structures, they suffer a major limitation as they are currently only available in straight sections. Whilst they can be used in a small number of applications, most concrete reinforcements involve many curved sections to take account of changes in the profile and the need to reinforce the beam in shear. The principal objective of this project is to develop the materials, methodology and manufacturing process for a low cost curved FRP rebar to enable the broad use of FRP rebar systems in European infrastructure. The research tasks will include: - Selection of composite materials for the new production process - Development and research of new process routes - Prototyping of curved non-ferrous rebar samples - Destructive testing of non-ferrous reinforcement samples - Experimental exposure testing - Design and manufacture of case study precast components - Structural testing of large scale case studies - Development of design guide and liaison with European Standards. The anticipated output from the project will be the ability to cost effectively manufacture curved FRP rebars, either in the factory or on site. If the project goals are achieved it is anticipated that the following key benefits will be realised: - Elimination of rebar corrosion - Reduction in the weight of the reinforcement by 75% - A 15% reduction in the volume of concrete used for on-site and precast reinforced concrete applications - An 80% reduction in the cost of maintenance of concrete structures - New European markets worth ¿200M and the creation of some 1700 jobs. Keywords: curved rebar, polymer composite, reinforced concrete.
Acronym: 
CURVEDNFR
Project ID: 
2 878
Start date: 
01-10-2002
Project Duration: 
33months
Project costs: 
1 000 000.00€
Technological Area: 
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.