Program Summary
A fully structural, noncorrosive, cost effective, strong, high quality, light, green, easy to install with least traffic impact solution for damaged/corroded piles and columns. Many of the piles and columns have sever corrosion issues due to exposure to various chemicals (deicing, other chemicals from industrial plants), seawater, sea moisture, rain, etc. To mitigate the issue, MSTBAR has introduced the GFRP Rebar Cage and GFRP shell to address these issues. The GFRP Rebar Cage is a noncorrosive, super strong & light, easy to install rebar cage which will be designed to transfer and take the full load, the GFRP shell will be both as a stay in place concrete form, as well as providing confinement and be a layer of protection to limit any further intrusion of chemicals into the structure. This approach will eliminate many steps in column repair as well as pile repairs/rehab (Concrete, Timber, Steel) in the water (For RC columns and piles just remove the spalled concrete, place the MSTBAR rebar cage, install the GFRP shell and fill the annular space with concrete).
Contact Information
Farokh Mehr, MS
408-318-4848
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www.mstbar.com
Detailed Description of Program
Describe your product/technology:
MSTBar GFRP Rebar Cage and GFRP Shell encasements are engineered solutions to address any structural issues with existing columns or piles (Timber, Steel, Concrete). With this solution one can ignore the existing pile or column and design the GFRP cage and concrete to take the full load based on AASHTO LRFD, or ACI 440.11-22 design guidelines and ASTM D7957 specs. MSTBAR will provide complementary design per loading requirements. Proper connection to the original column/pile are made to transfer the loads. If piles are in the water, proper load transfer will be added as needed (may require dive team), the GFRP rebar cage will be built in sections with proper overlap and lowered around pile, then the jackets are placed in section, the ends will be plugged, water will be pumped out (if possible) and annular space will be filled with filled with approved cementitious grout. The idea is minimizing dive time.
Materials are typically shipped within 3-4 weeks after design is approved, and purchase order is received. If one has issues with columns or piles, please provide the followings:
- Picture of existing column/pile and its condition
- Any NDT test, existing loading capacity, etc.
- Additional Loading capacity required by the GFRP encasement.
- The dimensions of encasement.
- Accessibility, distance between piles.
- If GFRP shell is required, or owner prefers to shotcrete the GFRP cage (roadside columns)
- The preferred geometry of the GFRP shell (Circular, Square or Rectangular), if shell is selected.
Why is it innovative?
It is fully structural, noncorrosive, green, light, low cost and easy to install.
In typical repair of corroded/spalled columns/piles, one must remove the corroded section, add additional steel reinforcement, add cathodic protection for the new steel rebars, form the column/pile add the required concrete/grout, then remove the forms, wait for full cure, surface prep the area and wrap them with FRP to stop further spalls. With MSTBAR system, only the spalled concrete must be removed, the GFRP rebar will be placed around the column/pile with minimum effort, to take the load and confine the concrete, since it is noncorrosive no cathodic protection is required. The GFRP Shell will act as both a form and confinement of concrete as well, then just add the concrete. This will eliminate many of the steps, saves time, construction cycle, traffic control, job site accidents are substentially reduced. Since the system is premanufactured with highest quality and it is light, these systems can be assembled in minimum time. MSTBAR system minimizes weather related issues as well. Once installed the shell could be painted with any UV protection paint, in addition to integrated UV protection in the shell to further the life of the structure for 100+ years.
What would a field demonstration entail?
Typically, provide MSTBAR with a picture of the structure and loading requirement, existing condition, dimensions etc., so the design can be performed.
Ideal cases would be selecting a spalled concrete column next to a freeway, corroded H-Pile, corrode steel encased concrete piles, corroded hallow steel piles, corroded Timber piles which needs retrofit.
MSTBAR will provide the design, once approved we will ship the material.
DOT will provide the crew and equipment to access, clean the piles and install the encasement.
MSTBAR will provide instructions, and supervision at the site.