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SPECIAL SPECIFICATION
4603
Glass Fiber Reinforced Polymer (GFRP)
1. Description. This Item shall govern for the furnishing, placing and construction methods for
Glass Fiber Reinforced Polymer (GFRP) reinforcement for concrete pavement or structural
slab, utilizing GFRP reinforcement in accordance with the details and at locations as shown
on the plans. Unless otherwise noted in this Item or in the plans, the Contractor will utilize
conventional casting procedures for concrete pavements and/or bridge slabs as detailed in
the plans.
2. Materials. All materials are to conform to the pertinent requirements of the following Items
except as required herein:
Item 360, Concrete Pavement
Item 420, Concrete Structures
Item 421, Hydraulic Cement Concrete
Item 422, Reinforced Concrete Slab
Item 426, Prestressing
Item 440, Reinforcing Steel
A. GFRP.
1. All fibers will be in the form of unidirectional rovings of a given size and mass.
Fiber sizings and coupling agents will be compatible with the resin system used to
impregnate them.
2. Commercial grades of vinyl ester and epoxy resin systems are permitted provided
the finished product meets the physical and durability requirements described
below. The base polymer in the resin system shall not contain any polyester.
Blending of vinyl ester and epoxy resins is permitted.
3. Styrene is permitted to be added to the polymer resin during processing. Added
styrene shall be less than 10 percent by mass of the polymer resin. The amount of
styrene, as a mass percentage of the polymer resin, added during processing will be
reported. Constituent content of resin shall be determined by ASTM D 3171. The
manufacturer shall produce GFRP bars using any variation of the pultrusion
process.
4. Commercial grade inorganic fillers such as kaolin clay, calcium carbonate, and
alumina trihydrate shall not exceed 20 percent by mass of the polymer resin
constituent.
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Commercial grade additives and process-aids, such as release agents, low-profile
shrink additives, initiators, promoters, hardeners, catalysts, pigments, fire-
retardants, and ultra-violet inhibitors are permitted and depend on the processing
method. Shrink additives, if used shall be less than 20 percent by mass of the
polymer resin. Commercial grade inorganic or organic non-woven surfacing mats
or veils are permitted.
5. All GFRP reinforcement will conform to the requirements shown in the AASHTO
Bridge Design Guide Specifications for GFRP Reinforced Concrete Bridge Decks
and Traffic Railings, on the plans, and as stated herein. All GFRP reinforcement
shall be deformed or sand coated.
B.
1. Material Properties. All Number 8, Number 6, and Number 5 GFRP
reinforcement will be in conformance with the following:
Material Property Minimum Maximum
or Nominal
Fiber Content (% by volume) 55 NA
Design Nominal Diameter (inches) 1.0(#8), 0.750(#6), 0.625(#5) NA
Design Nominal Area (sq. in.) 0.785(#8), 0.442(#6), 0.307(#5) NA
Minimum Guaranteed Ultimate Tensile
Strength (GUTS)(ksi) 80(#8), 90(#6), 95(#5) NA
Tensile Modulus of Elasticity (ksi) 5700 NA
Shear Strength (perpendicular to the bar fibers)(ksi) 18 NA
Ultimate Tensile Strain (%) 1.2 NA
Ultimate Bond Stress (psi) (ACI 440.3R Test 1400 NA
Method B.3)
Longitudinal Coefficient of Thermal Expansion 6.0E-06 10.0E-06
(per degree C)
Transverse Coefficient of Thermal Expansion 21.0E-06 23.0E-06
(per degree C)
Glass Transition Temperature ( per degree F) 212 NA
Moisture Absorption (%) NA 1.0
Longitudinal Wicking (continuous voids) 0
(5 consecutive 1cuts; a continuous void is one appearing in all 5 cuts)
2. Testing. Two (2) months prior to fabrication of the GFRP reinforcement, the
manufacturer is to furnish the Department two (2) copies of documentation
showing the composition, testing procedures to be utilized, and typical test values,
for the type of GFRP reinforcement being furnished for review and acceptance.
Submission of the documentation, along with representative samples (two 3 ft.
sections for each size to be furnished), will be made to the Construction Division,
Materials Section, Texas Department of Transportation, 125 E. 11th Street, Austin,
Texas, 78701-2483. Prior to shipment, all GFRP reinforcement produced for the
project will have representative samples (as agreed upon between the GFRP
reinforcement manufacturer and the Department) tested for the properties listed
above.
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Selected testing will be performed in the presence of a representative of the
Construction Division, Materials Section for material acceptance. Testing will be
performed in the United States.
3. Documentation. For all GFRP reinforcement to be used on Department projects,
the bar manufacturer is to furnish the Engineer two (2) copies of written
certifications that the GFRP reinforcement meets the requirements of this
specification. In addition, the certification is to list the test values and test
procedures used to determine the physical properties of the GFRP reinforcement.
Certifications bearing the notarized signature of a responsible authorized
representative of the bar manufacturer are required. Each bundle of GFRP
reinforcement will be identified with a corresponding lot number with the lot
numbers affixed to each bundle by means of a durable tag.
4. Repair Material. The material used to repair the cut ends of GFRP reinforcement
will comply with the requirements established by the bar manufacturer. All repairs
of cut ends will be performed at the GFRP reinforcement manufacturer's plant
unless otherwise authorized by the Engineer.
3. Construction. Unless otherwise shown on the plans, any one or combination of
conventional forming systems may be used within the same span, structure, or slab. The
Contractor will notify the Fabricator and the Engineer in writing as to the types of forming
and the diaphragm option he proposes to use in bridge structures that utilize GFRP
reinforcement in the slab. All other forming and construction methods shall be in accordance
with the above reference items as applicable.
4. Material Handling. Systems for handling GFRP reinforcement will have padded contact
areas. Bundling bands will be padded or suitable banding will be used to prevent damage to
the bars. Bundles of GFRP reinforcement are to be lifted with a strong back, spreader bar,
multiple supports, or a platform bridge. The GFRP reinforcement will not be dropped or
dragged.
5. Storage and Placement. GFRP reinforcement shall be stored above the surface of the
ground upon platforms, skids, or other supports as close as possible to the point of
placement. The bars shall be covered with opaque plastic or other types of cover to protect
the bars from the external environment. Prevent exposure of GFRP reinforcing bars to
temperature above 120F during storage.
The Contractor will accurately locate GFRP reinforcement. GFRP reinforcement will be
firmly held in place before and during concrete placement by means of ties and bar supports,
adequate in strength and number to prevent displacement and to keep the reinforcing at the
proper distance from the forms and in accordance with the requirements of Article 440.8,
Reinforcing Steel. Adequate vertical restraint of GFRP reinforcement will be provided to
prevent upward movement in the fresh concrete due to buoyancy. All accessories such as
ties, bar chairs, supports or clips will be non-ferrous. Plastic or precast mortar or concrete
block supports as approved by the Engineer may be used.
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When placed in the work, reinforcement should be free from dirt, paint, grease, oil, or other
foreign materials. Any such material present on the bars in significant quantities will be
removed before placing concrete by cleaning the bars using methods and materials
recommended by the bar manufacturer and approved by the Engineer.
Shear cutting will not be permitted on the GFRP reinforcement. High-speed grinder cutting
or hack saw cutting will be permitted with the permission of the Engineer. Cut ends will be
coated as specified in "Repair of Bar Damage" of this Item. All surface damage to GFRP
reinforcement is to be repaired as described in "Repair of Bar Damage" of this Item or the
bar replaced with an undamaged bar, as directed by the Engineer.
6. Repair of Bar Damage. All visible damage to the GFRP reinforcement, not resulting in
rejection of the damaged material by the Engineer, will be repaired. Damaged areas will be
repaired using materials and procedures specified by the GFRP manufacturer.
7. Concrete Placement. If the reinforcement is not adequately supported or tied to resist
settlement, floating upward, or movement in any direction during concrete placement,
concrete placement will be halted until corrective measures are taken. Vibrators used to
consolidate the concrete are to be equipped with non-metallic heads. Vibrator insertion
locations and consolidation time will be adjusted to ensure proper consolidation of the
concrete.
8. Bending. If bending of GFRP reinforcement is required in the plans, the bends shall be pre-
fabricated. No bending of GFRP reinforcement may be attempted in the field.
9. Measurement and Payment. GFRP reinforcement for concrete pavement, slabs or spans
utilized under this Item will not be measured or paid for directly, but will be considered
subsidiary to Item 422, Reinforced Concrete Slab of the type specified for the appropriate
bid item of the contract. The linear foot quantities of GFRP reinforcement shown on the
plans are estimates and are for the Contractors information only. The quantities of concrete
and GFRP reinforcement shown on the plans are based on conventionally formed concrete
pavements and/or reinforced concrete slabs.
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