LAMINATE MATERIAL FOR REINFORCEMENT, REINFORCING METHOD, AND REINFORCING STRUCTURAL BODY FOR STRUCTURE

Abstract

A laminate material for reinforcement is provided that can reduce on-site work steps and facilitate quality control of a resin to be used to achieve improvement in work efficiency, and that can suppress debonding of a reinforcing member to obtain a high reinforcing effect. A laminate material for reinforcement 10 bonded to and integrated with a surface to be reinforced of a structure 100 to reinforce the structure has a fiber-reinforced composite member 11, a high-elongation elastic resin layer 12 formed on a surface on a bonding side to the structure of the fiber reinforced composite member 11, and an intermediate resin layer 13 disposed between the fiber-reinforced composite member 11 and the high-elongation elastic resin layer 12.

Claims

1. A laminate material for reinforcement bonded to and integrated with a surface to be reinforced of a structure to reinforce the structure, the laminate material for reinforcement of the structure having: a fiber-reinforced composite member; a high-elongation elastic resin layer formed on a surface on a bonding side to the structure of the fiber-reinforced composite member; and an intermediate resin layer disposed between the fiber-reinforced composite member and the high-elongation elastic resin layer.

2. The laminate material for reinforcement of the structure according to claim 1, wherein the intermediate resin layer has a tensile elasticity when cured of 1000 N/mm.sup.2 or more and 10000 N/mm.sup.2 or less.

3. The laminate material for reinforcement of the structure according to claim 1, wherein the intermediate resin layer has a thickness of 0.05 mm or more and 5.0 mm or less.

4. The laminate material for reinforcement of the structure according to claim 1, wherein the intermediate resin layer is a thermosetting resin or a thermoplastic resin.

5. The laminate material for reinforcement of the structure according to claim 4, wherein the thermosetting resin forming the intermediate resin layer is an epoxy resin, an epoxy acrylate resin, an acrylic resin, an MMA resin, a vinyl ester resin, an unsaturated polyester resin, or a photosetting resin.

6. The laminate material for reinforcement of the structure according to claim 4, wherein the thermoplastic resin forming the intermediate resin layer is a polyamide resin, a nylon resin, a polypropylene resin, a phenolic resin, or an ABS resin.

7. The laminate material for reinforcement of the structure according to claim 1, wherein the high-elongation elastic resin layer has, when cured, a tensile elongation of 400% or more, a tensile strength of 8 N/mm.sup.2 or more, and a tensile elasticity of 60 N/mm.sup.2 or more and 500 N/mm.sup.2 or less.

8. The laminate material for reinforcement of the structure according to claim 1, wherein the high-elongation elastic resin layer is a polyurea resin, a urethane resin, or an epoxy resin.

9. The laminate material for reinforcement of the structure according to claim 8, wherein the polyurea resin forming the high-elongation elastic resin layer contains a base resin, a hardener, a filler and an additive, and is composed of: (i) the base resin: a prepolymer having an isocyanate as a reactive component and having a terminally-remaining isocyanate adjusted to 1 to 16 parts by weight in NCO weight % is used; (ii) the hardener: a hardener containing an aromatic amine as a main component is used, and the hardener having a ratio of NCO of the base resin to the amine calculated to 1.0:0.55 to 0.99 parts by weight is used; (iii) the filler: a silica stone powder, a thixotropic agent and the like are contained, and blended appropriately to 1 to 500 parts by weight; and (iv) the additive: a colorant, a viscosity modifier, a plasticizer and the like are contained, and blended appropriately to 1 to 50 parts by weight.

10. The laminate material for reinforcement of the structure according to claim 1, wherein the fiber-reinforced composite member is a reinforcing-fiber containing member containing reinforcing fibers and a resin impregnated into the reinforcing fibers and cured, a cross-sectional shape of the reinforcing-fiber containing member is a plate shape, an angle shape, a channel shape, a T-shape, or a square-pipe shape, and the intermediate resin layer and the high-elongation elastic resin layer are laminated on a surface on a bonding side to the structure of the reinforcing-fiber containing member.

11. The laminate material for reinforcement of the structure according to claim 10, wherein the resin of the fiber-reinforced composite member is a thermosetting resin or a thermoplastic resin, or a mixed resin of a thermosetting resin and a thermoplastic resin.

12. The laminate material for reinforcement of the structure according to claim 1, having a release sheet on an outer surface opposite to a laminating side to the fiber-reinforced composite member of the high-elongation elastic resin layer.

13. A reinforcing method for a structure for reinforcing the structure by bonding and integrating a laminate material for reinforcement to a surface to be reinforced of the structure with an adhesive, wherein the laminate material for reinforcement is a laminate material for reinforcement according to claim 1.

14. The reinforcing method for the structure according to claim 13, wherein the adhesive is an epoxy resin, an epoxy acrylate resin, an acrylic resin, an MMA resin, a vinyl ester resin, an unsaturated polyester resin, or a photosetting resin.

15. The reinforcing method for the structure according to claim 14, wherein the adhesive is an epoxy resin adhesive, and the epoxy resin adhesive is provided as being of a two-component type having a base resin and a hardener, and is composed of: (i) the base resin: a base resin containing an epoxy resin as a main component and, if necessary, containing a silane coupling agent and/or the like as an adhesion enhancer is used; and (ii) the hardener: containing amines as a main component.

16. The reinforcing method for the structure according to claim 13, having, before bonding the laminate material for reinforcement to the surface to be reinforced of the structure, a step of preparing the surface to be reinforced of the structure and/or a step of applying a primer.

17. A reinforcing structural body for a structure having a fiber-reinforced composite member bonded with an adhesive to and integrated with a surface to be reinforced of the structure, the structure reinforcing structural body for the structure having: the fiber-reinforced composite member; a high-elongation elastic resin layer formed on a surface on a bonding side to the structure of the fiber-reinforced composite member; and an intermediate resin layer disposed between the fiber-reinforced composite member and the high-elongation elastic resin layer, wherein the high-elongation elastic resin layer has, when cured, a tensile elongation of 400% or more, a tensile strength of 8 N/mm.sup.2 or more, and a tensile elasticity of 60 N/mm.sup.2 or more and 500 N/mm.sup.2 or less.

18. The reinforcing structural body for the structure according to claim 17, wherein the adhesive is an epoxy resin adhesive, and the epoxy resin adhesive is provided as being of a two-component type having a base resin and a hardener, and is composed of: (i) the base resin: a base resin containing an epoxy resin as a main component and, if necessary, containing a silane coupling agent and/or the like as an adhesion enhancer is used; and (ii) the hardener: containing amines as a main component.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0047] FIGS. 1(a) to 1(c) are cross-sectional views showing embodiments of a laminate material for reinforcement of the present invention;

[0048] FIGS. 2(a), 2(b) are diagrams for illustrating a reinforcing method and a reinforcing structural body for a structure using the laminate material for reinforcement of the present invention;

[0049] FIG. 3 is a schematic diagram illustrating an example of a producing method for a fiber-reinforced composite member constituting the laminate material for reinforcement of the present invention;

[0050] FIGS. 4(a) to 4(f) are diagrams for illustrating various shapes of embodiments of the laminate material for reinforcement of the present invention, FIG. 4(a) being a perspective view, FIGS. 4(b) to 4(f) being cross-sectional views;

[0051] FIG. 5(a) is a schematic diagram illustrating another example of a producing method for the fiber-reinforced composite member constituting the laminate material for reinforcement of the present invention, and FIGS. 5(b), 5(c) are diagrams illustrating an embodiment of a producing method for the laminate material for reinforcement of the present invention;

[0052] FIG. 6 is a perspective view showing an embodiment of the fiber-reinforced composite member constituting the laminate material for reinforcement of the present invention;

[0053] FIG. 7 is a diagram showing an embodiment of a fiber sheet that may be used in the laminate material for reinforcement of the present invention;

[0054] FIGS. 8(a), 8(b) are cross-sectional views showing examples of a fiber-reinforced plastic strand constituting the fiber sheet that may be used in the laminate material for reinforcement of the present invention;

[0055] FIG. 9 is a process diagram illustrating an embodiment of the reinforcing method for a structure of the present invention;

[0056] FIGS. 10(a) to 10(d) are diagrams illustrating the summary of a concrete specimen in a tester for proving the effectiveness of the laminate material for reinforcement and the reinforcing method of the present invention;

[0057] FIG. 11 is a graph showing strain distributions of reinforcing member samples when a maximum load is applied for comparing experimental examples of the present invention and comparative examples;

[0058] FIG. 12 is a graph showing maximum loads in an experiment of the reinforcing member samples for comparing the experimental examples of the present invention and the comparative examples;

[0059] FIG. 13 is a diagram for illustrating an example of a conventional structure reinforcing method; and

[0060] FIG. 14 is a diagram for illustrating another example of a conventional structure reinforcing method.

EMBODIMENTS OF INVENTION

[0061] Hereinafter, a laminate material for reinforcement, a reinforcing method, and a reinforcing structural body for a structure according to the present invention will be described in further detail in accordance with the drawings.

[0062] With reference to FIG. 1(a), an embodiment of a laminate material for reinforcement 10 of a structure according to the present invention is shown. According to the present embodiment, the laminate material for reinforcement 10 of the present invention has a fiber-reinforced composite member 11, a high-elongation elastic resin layer 12 formed on a surface on a bonding side to a structure of the fiber-reinforced composite member 11, and an intermediate resin layer 13 disposed between the fiber-reinforced composite member 11 and the high-elongation elastic resin layer 12.

[0063] In addition, if necessary, as shown in FIG. 1(b), adhesion performance between the intermediate resin layer 13 and the high-elongation elastic resin layer 12 may also be improved further by forming a primer layer 14 between the intermediate resin layer 13 and the high-elongation elastic resin layer 12.

[0064] Furthermore, as shown in FIG. 1(c), on an outer surface opposite to a laminating side to the fiber-reinforced composite member 11 of the high-elongation elastic resin layer 12 in the laminate material for reinforcement 10, a release sheet 60 may be provided in a laminating manner in order to protect the high-elongation elastic resin layer 12. When the laminate material for reinforcement 10 is used, this release sheet 60 is peeled off.

[0065] According to a preferred aspect of the present invention, the high-elongation elastic resin layer 12 has, when cured, a tensile elongation of 400% or more, a tensile strength of 8 N/mm.sup.2 or more, and a tensile elasticity of 60 N/mm.sup.2 or more and 500 N/mm.sup.2 or less. However, such physical properties of the high-elongation elastic resin layer 12 may be varied appropriately according to high-elongation elastic resins to be used, may be selected according to requisite reinforcement strengths of structures, and are not limited to the properties mentioned above.

[0066] The laminate material for reinforcement 10 of the present invention thus configured, as shown in FIGS. 2(a), 2(b), is bonded to and integrated with a surface of a structure 100 via an adhesive 20 to form a reinforcing structural body 200 of the structure 100. The structure 100 may be, as mentioned above, a steel structure, such as a bridge, a pier, or a chimney, and furthermore, such as a watercraft, a vehicle, or an aircraft, a concrete structure that is an architectural or civil-engineering construction, such as beam and purlin members, a wall, a pillar, and a slab member such as a floor slab, and furthermore, an FRP (fiber-reinforced plastic) structure, a steel-concrete composite structure, a steel-FRP composite structure, a concrete-FRP composite structure, or any other structures of various kinds.

[0067] Next, each of members constituting the laminate material for reinforcement 10 according to the present invention will be described.

Fiber-Reinforced Composite Member

[0068] The fiber-reinforced composite member 11 constituting the laminate member for reinforcement 10 is a reinforcing-fiber-containing member containing reinforcing fibers that have a resin impregnated therein and cured, and, as described later in further detail, a transverse cross-sectional shape thereof may be formed into various shapes, for example, it may be like a plate such as a flat plate, or alternatively, an angle shape, a channel shape, a T-shape, or a shape like a square pipe or the like, other than a flat plate. However, in the present description, hereinafter, the continuous fiber-reinforced composite member 11 may be referred to simply as FRP plate.

[0069] As the reinforcing fibers of the FRP plate 1, PAN-based or pitch-based carbon fibers, glass fibers, basalt fibers; metal fibers such as boron fibers, titanium fibers, or steel fibers; or furthermore organic fibers such as aramid, PBO (polyparaphenylene benzobisoxazole), polyamide, polyarylate or polyester may be used alone, or a plurality of these different kinds of fibers may be mixed and used in a hybrid form.

[0070] In addition, the resin impregnated into the reinforcing fibers of the FRP plate 11 may be a thermosetting resin or a thermoplastic resin, or may be a mixed resin of a thermosetting resin and a thermoplastic resin. As the thermosetting resin, a cold setting type or thermosetting type of epoxy resin, vinyl ester resin, MMA resin, acrylic resin, unsaturated polyester resin, phenolic resin or the like may be used suitably, and, as the thermoplastic resin, nylon, vinylon or the like may be used suitably. In addition, the fiber content of the FRP plate 11 is 30% to 70% by volume, preferably, 40% to 60% by volume.

[0071] Persons having ordinary skill in the art may produce the FRP plate 11 by well-known various methods. For example, when a thermoplastic resin is used as a resin R, the FRP plate 11 may be produced by a pultrusion process. In this case, for example, as shown in FIG. 3, first of all, reinforcing fibers f are introduced into a resin bath 31 from creels 30, and impregnated into the resin R. The reinforcing fibers impregnated with the resin is formed into a predetermined cross-sectional shape and simultaneously cured using a heated die 33 equipped with a heater 32 to form a desired FRP plate 11 continuously. The FRP plate 11 formed into the predetermined cross-sectional shape is pulled out from a die 32 by a puller 34 and, if necessary, may be subjected to a heating process further in a post-curing furnace 35.

[0072] The FRP plate 11 is so produced as to have such a long length as 50 m or more, and may be rolled up, or may also be cut to any length such as 1 to 10 m, at the outlet of the puller 34 or the post-curing furnace 35. In should be noted that the intermediate resin layer 13 and the high-elongation elastic resin layer 12, which will be described later in detail, though not shown, may be laminated by applying their respective resins with applicators downstream from the outlet of the heated die 33, or may also be laminated by applying their respective resins with applicators after the FRP plate 11 is cut at the outlet of the heated die 33.

[0073] In addition, as shown in FIG. 1(c), when the release sheet 60 like a polyethylene film, for example, is laminated on the outer surface of the high-elongation elastic resin layer 12 of the laminate material for reinforcement 10 in order to protect the high-elongation elastic resin layer 12, it is preferred that the release sheet 60 be attached before or immediately after the high-elongation elastic resin layer 12 laminated on the FRP plate 11 dries.

[0074] When the FRP plate 11 produced by the above pultrusion process uses, for example, carbon fibers as the reinforcing fibers f, a plurality of fiber bundles each of which is not impregnated with a resin of 6000 to 24000 bundled monofilaments (carbon fiber monofilaments) f having an average diameter of 7 m, for example, are paralleled unidirectionally and used.

[0075] In addition, the FRP plate 11 is a long object extending in an axial direction, which is, in the above description, as shown in FIG. 4(a), a thin sheet-like object whose length in a thickness direction (T11) is made smaller than its length in a width direction (W11) in a transverse cross section (W11>T11), and typically has a rectangular cross section having a width (W11) of 35 to 150 mm and a thickness (T11) of 1 to 4 mm. In addition, a length (L11) in the axial direction may be any length, but, typically, 1 m or more and 100 m or less, or, in some cases, 100 m or more. It should be noted that the length in the width direction (W11) and the length in the thickness direction (T11) may be the same (W11=T11), or the length in the thickness direction (T11) may also be made larger than the length in the width direction (W11) (W11<T11).

[0076] Furthermore, the transverse cross-sectional shape of the FRP plate 11, as described above, may be formed into various shapes, and it is not limited to a shape like a plate such as a flat plate shown in in FIG. 4(a). Alternatively, as shown in FIGS. 4(b) to 4(f), it may also be a shape such as an angle shape in which a horizontal plate 11a and a vertical plate 11b form an L-shape (FIG. 4(b)), a channel shape in which a horizontal plate 11a and vertical plates 11b formed at both ends thereof form a recessed groove shape (FIG. 4(c)), a T-shape in which a horizontal plate 11a and one or two (or more) vertical plates 11b formed thereon form a T-shape (FIGS. 4(d), 4(e)), or a square-pipe shape in which a plurality of flat plates 11a are combined and formed integrally (FIG. 4(f)). It should be noted that the intermediate resin layer 13 and the high-elongation resin layer 12, as shown by the dashed line, are laminated in a range of the horizontal plate 11a that is a bonding face to a structure of these FRP plates 11.

[0077] On the other hand, when the impregnating resin R is a thermoplastic resin, for example, as shown in FIG. 5, the FRP plate 11 may also be produced by pressing a resin film 41 having the resin R applied thereto against the reinforcing fibers f fed from a creel 40 from one side or both sides by heated pressure rollers 42 to impregnate the resin thereinto, and thereafter curing the resin in a cooling furnace 43. Of course, though not shown, the FRP plate 11 may also be produced by applying a resin on one side or both sides of the reinforcing fibers f using such an applicator as a resin coater, or using an extruding machine (extruder)), and thereafter curing the resin.

[0078] As an alternative method, the FRP plate 11 constituting the laminate material for reinforcement 10, as shown in FIG. 6, may also be produced by impregnating the resin R into the fiber sheet 1 containing the reinforcing fibers f and curing the resin R. In this case, the FRP plate 11 has any sheet-like or plate-like shape.

[0079] The fiber sheet 1 may be a unidirectionally-aligned fiber sheet in which the continuous fibers f are aligned unidirectionally along a longitudinal direction of the FRP plate 11. For example, when carbon fibers are used as the reinforcing fibers f, a plurality of fiber bundles each of which is not impregnated with a resin of 6000 to 24000 bundled monofilaments (carbon fiber monofilaments) f having an average diameter of 7 m, for example, are paralleled unidirectionally and used. The fiber weight of the carbon fiber sheet 1 is typically 30 to 1000 g/m.sup.2.

[0080] Though in the above description the fiber sheet 1 is a unidirectionally-aligned fiber sheet in which the continuous fibers f are aligned unidirectionally along the longitudinal direction of the FRP plate 11, in some cases, the fiber sheet 1 made of cloth (fabric) that is a plain weave fabric, a twill fabric or a satin fabric in which the reinforcing fibers are aligned in two directions, or a triaxial or quadraxial fabric in which the reinforcing fibers are aligned in three or four directions. In addition, the cloth may be composed of a single fabric sheet, or may also be composed of a plurality of fabric sheets having the same or difference configurations that are laminated with one another. Furthermore, the fiber sheet 1 may also be one formed in a sheet-like shape using mat-like or felt-like reinforcing fibers. Of course, the fiber sheet 1 may also be formed by laminating the above various forms of fiber sheets in combination.

[0081] Furthermore, the fiber sheet 1, as shown in FIGS. 7, 8(a), 8(b), uses a fiber sheet 1 in which a plurality of thin continuous fiber-reinforced plastic strands 2 in which a matrix resin Re has been impregnated and cured are paralleled into a bamboo-blind-like shape in the longitudinal direction, and the strands 2 are each fastened to one another with a strand fastening member 3. In this regard, the fiber-reinforced plastic strand 2 may have a substantially-circular cross-sectional shape (FIG. 8(a)) that is 0.5 to 3 mm in diameter (d), or a substantially-rectangular cross-sectional shape (FIG. 8(b)) that is 1 to 10 mm in width (w) and 0.1 to 2 mm in thickness (t). Of course, if necessary, any other various cross-sectional shapes may be taken. As described above, in the fiber sheet 1 having the strands 2 paralleled unidirectionally into a bamboo-blind-like shape, the strands 2 are each close to but separated from one another with an air gap (g)=0.05 to 3.0 mm, and fastened with the strand fastening members 3 disposed at intervals P, for example.

[0082] Using the fiber sheet 1 made by paralleling the plurality of fiber-reinforced plastic strands 2 into a bamboo-blind-like shape in the longitudinal direction, a plate-like continuous fiber-reinforced composite member, namely the FRP plate 11, is produced by applying the resin R on this fiber sheet 1, filling the sheet surface and the air gap (g) formed between the individual strands 2, 2 with the resin R, and curing the resin. The resin R may be the same as the matrix resin Re impregnated into the fiber-reinforced plastic strand 2, or may be a different resin.

High-Elongation Elastic Resin Layer

[0083] According to the present invention, the high-elongation elastic resin layer 12 is disposed via the intermediate resin layer 13 on one side, namely a surface on a bonding side to the structure 100, of the fiber-reinforced composite member (FRP plate) 11 described above. This high-elongation elastic resin layer 12 in FIG. 1(a), 1(b) is formed by applying a high-elongation elastic resin 12a on a predetermined thickness (T12) and curing it. As the high-elongation elastic resin 1a, a polyurea resin, a urethane resin, an epoxy resin or the like may be used, and are selected appropriately according to the kinds of structures to be reinforced and desired degrees of reinforcement. For example, when a high degree of reinforcement as to be unaffected by temperature or the like is required, a polyurea resin, a urethane resin or the like that has low elasticity is used suitably. This point will be described later in further detail.

[0084] The application thickness (T12) of the high-elongation elastic resin 12a, namely the thickness (T12) of the high-elongation elastic resin layer 12, is set appropriately according to the thickness (T11) of the FRP plate 11 to be used and/or surface roughness of a bonded face 102 of a structure to which the laminated material for reinforcement 10 is applied. Generally, the application thickness (T12) of the high-elongation elastic resin 12a, namely the thickness (T12) of the high-elongation elastic resin layer 12, is about 0.05 to 3.0 mm. If the thickness of the high-elongation elastic resin layer 12 is less than 0.05 mm, there is the problem that concentration of a bonding stress cannot be reduced, or if it is more than 3.0 mm, the problem occurs that stress transmission required as a reinforcing effect is not sufficiently achieved. Typically, it is 0.5 to 1.5 mm.

[0085] Now, a polyurea resin having low elasticity, which is preferred as the high-elongation elastic resin 12a that forms the high-elongation elastic resin layer 12, will be described. The polyurea resin 12a having low elasticity suitable for forming the high-elongation elastic resin layer 12 contains a base resin, a hardener, a filler, an additive and the like, and an example of the composition thereof is as follows:

[0086] (i) Base Resin: a prepolymer having an isocyanate as a reactive component (for example, 4,-4 diphenylmethanediisocyanate) and having a terminally-remaining isocyanate adjusted to 1 to 16 parts by weight in NCO weight % is used.

[0087] (ii) Hardener: a hardener containing an aromatic amine (for example, an amine value of 80 to 90) as a main component is used, and the hardener having a ratio of NCO of the base resin to the amine calculated to 1.0:0.55 to 0.99 parts by weight is used. Furthermore, p-toluenesulfonic acid or the like may be contained as a hardening accelerator.

[0088] (iii) Filler: a silica stone powder, a thixotropic agent and the like are contained, and blended appropriately to 1 to 500 parts by weight.

[0089] (iv) Additive: a colorant, a viscosity modifier, a plasticizer and the like are contained, and blended appropriately to 1 to 50 parts by weight.

[0090] The polyurea resin having the above composition has, when cured, a tensile elongation of 400% or more (typically, 400 to 600%), a tensile strength of 8 N/mm.sup.2 or more (typically, 8 to 10 N/mm.sup.2), and a tensile elasticity of 60 N/mm.sup.2 or more and 500 N/mm.sup.2 or less (typically, 60 to 100 N/mm.sup.2).

[0091] For example, in a case such as when reinforcement of a steel structure is performed, the problem may occur that the high-elongation elastic resin layer 12 cannot achieve requisite reinforcing stress transmission if the elasticity is less than 60 N/mm.sup.2, or has insufficient elongation performance if it is more than 100 N/mm.sup.2, in particular, more than 500 N/mm.sup.2.

[0092] Tables 1, 2 below show the results of comparison between physical properties that an epoxy resin which may be used as a material which forms the high-elongation elastic resin layer 12 in the present invention has and physical properties that a polyurea resin having the above composition has.

TABLE-US-00001 TABLE 1 Epoxy Resin Polyurea Resin Tensile Elongation 100-200% 423% Tensile Strength 0.1-50 N/mm.sup.2 8.04 N/mm.sup.2 Tensile Elasticity 0.1-50 N/mm.sup.2 61.3 N/mm.sup.2 Filler Content 0-50 mass % 33.1 mass % Application Thickness 0.5 to 1.5 mm 0.5 to 1.5 mm Provision

TABLE-US-00002 TABLE 2 Relation between Temperature and Tensile Elasticity of High-Elongation Elastic Resin Layer Test Temperature Epoxy Resin Polyurea Resin 20 C. 1600 N/mm.sup.2 99.2 N/mm.sup.2 0 C. 1500 N/mm.sup.2 85.1 N/mm.sup.2 23 C. 100 N/mm.sup.2 61.3 N/mm.sup.2 40 C. 12 N/mm.sup.2 61.0 N/mm.sup.2 60 C. 12 N/mm.sup.2 61.0 N/mm.sup.2

[0093] The results in Table 1 above and the relational table (Table 2) of temperature and elasticity of the high-elongation elastic resin layer show that, if an epoxy resin is used, the material strength of the epoxy resin lowers, in particular, at high temperature, and the elongation performance lowers at low temperature in winter.

[0094] In contrast, the polyurea resin can exhibit stable performance from 20 C. to +70 C. Therefore, the polyurea resin can be used, for example, as the high-elongation elastic resin layer of the laminate material for reinforcement in order to reinforce a steel structure to achieve debonding prevention and repair and reinforcing effects that are unaffected by temperature, and, in particular, can be used highly suitably for a reinforcing method for a steel structure. It should be noted that a urethane resin may also exhibit similar performance to the polyurea resin.

Intermediate Resin Layer

[0095] According to the present invention, the laminate material for reinforcement 10 of the present invention has the intermediate resin layer 13 disposed between the fiber-reinforced composite member 11 and the high-elongation elastic resin layer 12.

[0096] That is, according to the present invention, on one side of the fiber-reinforced composite member (FRP plate) 11 described above, namely a side on which the high-elongation elastic resin layer 12 is disposed, the intermediate resin layer 13 is formed before the high-elongation elastic resin layer 12 is formed. The intermediate resin layer 13 is formed by applying an intermediate resin 13a on the FRP plate to a predetermined thickness (T13), and curing it. As the intermediate resin 13a, a thermoplastic resin or a thermosetting resin can be used, as the thermosetting resin, a cold setting type or thermosetting type of epoxy resin, epoxy acrylate resin, acrylic resin, MMA resin, vinyl ester resin, unsaturated polyester resin, photosetting resin or the like may be used suitably, and, as the thermoplastic resin, a polyamide resin, a nylon resin, a polypropylene resin, a phenolic resin, an ABS resin or the like may be used suitably.

[0097] The application thickness (T13) of the intermediate resin 13a, namely the thickness (T13) of the intermediate resin layer 13 is, generally, 0.05 mm or more and 5.0 mm or less (preferably, 3.0 mm or less). If the thickness of the intermediate resin layer 13 is less than 0.05 mm, such a functional effect as debonding prevention between the high-elongation elastic resin layer 12 and the FRP plate 11 is not provided, or if it is more than 3.0 mm, in particular, more than 5.0 mm, the plate becomes thick. Not only is it uneconomical, but also the elongation at fracture of the intermediate resin layer 13 is low, and consequently a failure of the intermediate resin layer 13 occurs. Typically, it is about 0.1 to 2.0 mm.

[0098] In this regard, the intermediate resin layer 13 has, when cured, a tensile elasticity of 1000 N/mm.sup.2 or more and 10000 N/mm.sup.2 or less. If the tensile elasticity is less than 1000 N/mm.sup.2, requisite reinforcing stress transmission cannot be achieved, or, conversely, if it is more than 10000 N/mm.sup.2, in particular, more than 5000 N/mm.sup.2, the problem that the elongation performance becomes insufficient occurs. Therefore, typically, the tensile elasticity is 1000 to 5000 N/mm.sup.2.

[0099] It should be noted that, as described above with reference to FIG. 1(b), if necessary, the primer layer 14 may also be formed between the intermediate resin layer 13 and the high-elongation elastic resin layer 12 to improve adhesion performance between the intermediate resin layer 13 and the high-elongation elastic resin layer 12 further. As the primer layer 14, for example, a urethane resin, an epoxy-modified urethane resin, an epoxy resin or the like is used suitably. The thickness is, though not particularly limited to, typically, about 0.01 mm to 2.0 mm.

[0100] It should be noted that, as described above with reference to FIG. 3, when the FRP plate 11 is produced by a pultrusion process, the intermediate resin layer 13 and the high-elongation elastic resin layer 12 may be laminated by applying their respective resins downstream from the outlet of the heated die 33, or may be laminated by applying their respective resins after the FRP plate 11 is cut at the heated die outlet.

[0101] Furthermore, as shown in FIG. 5(b), a film-like or tape-like high-elongation elastic resin layer 12 may also be produced by carrying the high-elongation elastic resin 12a on a release paper 70, if necessity, and bonded to the FRP plate 11 after the intermediate resin layer 13a is applied to this high-elongation elastic resin layer 12. In addition, as shown in FIG. 5(c), a high-elongation elastic resin layer 12 that has been preformed into a film or tape shape carried by the release paper 70, if necessity, may also be bonded to the FRP plate 11 having the intermediate resin 13a applied thereto. Of course, the high-elongation elastic resin layer 12 and the FRP plate 11 may also be bonded together after the intermediate resin 13a is applied to both of them.

Reinforcing Method

[0102] Next, a reinforcing method for a structure will be described. As described above with reference to FIGS. 2(a), 2(b), according to the present invention, reinforcement of the structure 100 is performed using the laminate material for reinforcement 10 manufactured in the above manner. Hereinafter, a reinforcing method for a structure according to the present invention may be referred to as laminate material bonding method.

[0103] According to the laminate material bonding method of the present invention, the laminate material for reinforcement 10 is integrated. with a surface of a structure via the adhesive 20. In this manner, the reinforcing structural body 200 for the structure having the FRP plate 11, the intermediate resin layer 13 and the high-elongation elastic resin layer 12 is formed.

[0104] When the structure 100 is reinforced, by bonding the FRP plate 11 to a member (structure) that is subjected mainly to a bending moment and an axial force such that the direction of orientation of the reinforcing fibers f of the FRP plate 11 roughly coincides with the main stress direction of a tensile stress or a compressive stress caused by the bending moment, the FRP plate 11 bears the stress effectively, so that the load bearing capacity of the structure can be improved efficiently.

[0105] In addition, when bending moments act in two directions orthogonal to each other, improvement of the load bearing capacity can be achieved efficiently by laminating and bonding two or more layers of fiber sheets 1 orthogonally such that the direction of orientation of the reinforcing fibers f of the FRP plate 11 roughly coincides with the main stress caused by the bending moment. Next, the laminate material bonding method will be described in further detail with reference to FIG. 9.

First Step

[0106] In order to perform the laminate material bonding method of the present invention, first of all, as shown in FIG. 9(a), 9(b), a surface to be bonded 101 of the structure 100 is prepared, if necessary, by removing a brittle portion 101a of a surface to be reinforced (that is, the surface to be bonded) 101 of the structure 100 with a grinding means 50 such as a disk sander, sandblasting, steel shot blasting, waterjetting, or the like.

Second Step

[0107] An epoxy resin primer 103 is applied to a prepared surface 102 (FIG. 9(c)). The primer 103 is not limited to epoxy-resin-based primers, and an MMA-based resin or the like is selected appropriately according to the materials of the adhesive 20 and the structure 100 to be reinforced. It should be noted that the step of applying the primer 103 may also be omitted.

Third Step

[0108] As shown in FIG. 9(d), the adhesive 20 is applied to the surface to be bonded of the structure 100 to be reinforced. The spread is, typically, about 1.0 to 5.0 kg/m.sup.2.

Fourth Step

[0109] Next, as shown in FIGS. 9(e), 9(f), the high-elongation elastic resin layer 12 of the laminate material for reinforcement 10 is placed facing the surface to be bonded of the structure 100, and then the laminate material for reinforcement 10 is pressed thereto. In this manner, the laminate material for reinforcement 10 is bonded to the structure surface 102 via the adhesive 20. At this time, if necessary, a surface of the high-elongation elastic resin layer 12 that becomes a bonded surface of the laminate material for reinforcement 10 may be prepared with a sandpaper, or a primer may be applied thereto. In addition, as shown in FIG. 1(c), when the release sheet 60 is laminated on the surface of the laminate material for reinforcement 10, bonding is performed after this release sheet 60 is removed.

[0110] The adhesives 20 include an epoxy resin, an epoxy acrylate resin, an acrylic resin, an MMA resin, a vinyl ester resin, an unsaturated polyester resin, a photosetting resin or the like, and, specifically, a cold setting type epoxy resin and an MMA resin are preferred.

[0111] In the present embodiment, an epoxy resin adhesive is used. The epoxy resin adhesive is provided as being of a two component type having a base resin and a hardener, and an example of its composition is as follows:

[0112] (i) Base resin: a base resin containing an epoxy resin as a main component and, if necessary, containing a silane coupling agent as an adhesion enhancer is used. The epoxy resin may be, for example, a bisphenolic epoxy resin, in particular, a rubber-modified epoxy resin for imparting toughness, and furthermore, a reactive diluent, a filler and a thixotropic agent may also be added according to the intended use.

[0113] (ii) Hardener: a hardener containing amines as a main component, and, if necessary, containing a curing accelerator and a filler, and containing a colorant or the like as an additive may be used. The amines may be, for example, an aliphatic amine containing meta-xylenediamine and isophoronediamine.

[0114] It should be noted that, though described as being applied to the structure surface, the adhesive 20 may also be applied to the high-elongation elastic resin layer 12 of the laminate material for reinforcement 10 or to both the surface of the structure 100 and the surface to be bonded of the high-elongation elastic resin layer 12.

[0115] Next, the following experiment was conducted in order to prove the effectiveness (adhesion performance) of the high-elongation elastic resin layer 12 and the intermediate resin layer 13 in the laminate material for reinforcement 10 according to the present invention, and the functional effects of the reinforcing method (laminate material bonding method) and the reinforcing structural body for a structure according to the present invention.

Experiment Summary (Experimental Examples 1, 2, Comparative Examples 1 to 3)

Material Properties of Materials Used

[0116] In the present experiment, in Experimental Examples 1, 2, using the laminate material for reinforcement 10 according to the present invention as a reinforcing member sample S that is attached to a concrete structure, a concrete specimen 100T as a concrete structure 100 was reinforced according to the laminate material bonding method. The FRP plate 11 used in the present experiment was such as described above with reference to FIG. 6, in which the resin R was impregnated into reinforcing fibers in which continuous reinforcing fibers f were aligned unidirectionally, and cured.

[0117] The FRP plate 11 was produced by a pultrusion process using an epoxy resin as the impregnating resin R to PAN-based carbon fibers as the reinforcing fibers f that were 7 m in in average diameter and 24000 in bundle number. The FRP plate 11 used in the test was 50 mm in width (W11), 1200 mm in length (L11), and 1 mm in thickness (T11).

[0118] The laminate material for reinforcement 10 according to the present invention used in Experimental Examples 1, 2 had the configuration shown in FIG. 1(b). That is, a two-part epoxy resin (made by NIPPON STEEL & SUMIKIN MATERIALS CO., LTD.: product name FR-WE7) was applied as the intermediate resin to the above FRP plate 11 to form the intermediate resin layer 13. Then, a two-part epoxy-modified urethane resin primer (made by NIPPON STEEL & SUMIKIN MATERIALS CO., LTD.: product name FP-UL1) was applied to form the primer layer 14, after the primer layer 14 dried to the touch, furthermore, a polyurea resin having the above composition was applied as the high-elongation elastic resin to the intermediate resin layer 13 to form the high-elongation elastic resin layer 12, and the laminate material for reinforcement 10 was thus produced. The application thicknesses of the epoxy resin and the polyurea resin, namely the thicknesses of the intermediate resin layer 13 and the high-elongation elastic resin layer 12, were T13=0.18 mm and T12=0.8 mm, respectively. In addition, the above primer layer 14 was 0.03 mm in thickness.

[0119] In the present experiment, in Comparative Examples 1, 2, reinforcing member samples S were different from the laminate material for reinforcement 10 in Experimental Examples 1, 2 described above, and were ones having the high-elongation elastic resin layer 12 formed by applying the high-elongation elastic resin 12a directly on the FRP plate 11, and not having the intermediate resin layer 13. In addition, in Comparative Example 3, a reinforcing member sample S was merely the FRP plate 11, and a configuration was adopted in which the FRP plate 11 was bonded directly to the concrete specimen 100T with an adhesive according to a conventional method.

[0120] Tables 3, 4 below show the material properties of the FRP plate 11 and the material properties of the epoxy resin (the intermediate resin layer 13 and the adhesive 20) and the polyurea resin (the high-elongation elastic resin layer 12) that were used. In addition, Table 5 shows the results of the present experiment regarding Experimental Examples 1, 2 and Comparative Examples 1 to 3.

[0121] In this regard, symbols in each specimen name listed in Table 5, FIG. 11, FIG. 12 are as follows:

First number: Plate thickness
HT: High-strength type
S: Having the high-elongation elastic resin layer (polyurea resin)
N: Not having the high-elongation elastic resin layer (polyurea resin)
PP: Having the intermediate resin layer (epoxy resin)
PN: Not having the intermediate resin layer (epoxy resin)
Final number: Specimen number

TABLE-US-00003 TABLE 3 Material Property Values of FRP Plate Test Item Test Result Tensile Elasticity (N/mm.sup.2) 167,000 Tensile Strength (N/mm.sup.2) 2,400 Unit Volume Weight (kg/m.sup.3) 1,600

TABLE-US-00004 TABLE 4 Material Property Values of Resins Used (Unit: N/mm.sup.2) High- Elongation Intermediate Elastic Resin Resin Layer Layer Adhesive (Epoxy (Polyurea (Epoxy Resin) Resin) Resin) Compressive 3,778 34 7,230 Elasticity Tensile Elasticity 3,350 20 5,300 Compressive 98 6.8 96.0 Strength Tensile Strength 73 12 37.0 Bending Strength 124 63.0 Tensile Shear 15.8 5.6 16.6 Strength

TABLE-US-00005 TABLE 5 Test Results Pmax(kN) max(N/mm.sup.2) Gf(N/mm) Mea- Aver- Mea- Aver- Mea- Aver- Specimen sured age sured age sured age Name Value Value Value Value Value Value Exp. 1HTS- 134 128 2.26 2.17 5.34 4.93 Ex. 1 PP1 Exp. 1HTS- 123 2.08 4.51 Ex. 2 PP2 Comp. 1HTS- 106 108 1.80 1.83 3.36 3.50 Ex. 1 PN1 Comp. 1HTS- 110 1.87 3.63 Ex. 2 PN2 Comp. 1HTN 65 1.1 1.3 Ex. 3

Tester

[0122] In Experimental Examples 1, 2 and Comparative Examples 1, 2 of the present experiment, two specimens were produced for each, and, in order to confirm adhesion performance between the FRP plate 11 and the high-elongation elastic resin layer 12, examination of the adhesion performance was conducted considering the presence or absence of the intermediate resin layer 13 to he a factor.

[0123] In FIGS. 10(a) to 10(d), the summary of the concrete specimen 100T in a tester and the positions of attached strain gauges G are shown. The dimensions of the concrete specimen 100T were 1501501200 mm, and the reinforcing member sample S used in the test was 50 mm wide1200 long1 mm thick, and attached to both surfaces of the concrete specimen 100T. In addition, in order to observe a stress distribution of the reinforcing member sample S, the strain gauges G were attached at intervals of 40 mm.

[0124] On the left side of FIG. 10(a) is a measuring part, on the right side is a fastening part, and the fastening part clamped the reinforcing member samples S and the concrete specimen 100T together with bolts via an iron plate for fastening. In a central portion of the concrete specimen, as shown in FIG. 10(b), a steel rod 100TR inside the concrete specimen was split in the middle, and a notch and a plywood made of plastic (plastic plywood) 100Tp having a width of 4 mm and a thickness of 2.5 mm were buried in a middle portion of the specimen in order to induce cracking.

[0125] The reinforcing member sample S was bonded to the concrete specimen 100T via the two-part epoxy resin adhesive (made by NIPPON STEEL & SUMIKIN MATERIALS CO., LTD.: product name FE-Z) 20 having the material property values shown in Table 2 above.

[0126] The test was conducted by an axial tensile loading method in which the concrete specimen 100T was placed having an axis disposed vertically extending in a portal frame, and the steel rods 100TR at both ends were pulled upward and downward using a hydraulic jack. It should be noted that the loading speed was 5 kN/min.

[0127] It should be noted that the compressive strength of concrete of the concrete specimen 100T used in the present experiment was 49.8 N/mm.sup.2, the tensile strength thereof was 4.3 N/mm.sup.2, and the Young's modulus (tensile elasticity) thereof was 34000 N/mm.sup.2.

[0128] In Experimental Examples 1, 2 and Comparative Examples 1, 2 of the present experiment, the reinforcing member sample S reinforced the concrete specimen 100T in the following manner using a similar method to one described with reference to FIG. 9.

[0129] First of all, a surface to be reinforced of the concrete specimen 100T were ground and cleaned by shot blasting to be a moderately-rough surface. A two-part epoxy-modified urethane primer (FORCAUL-1 (product name) made by NIPPON STEEL & SUMIKIN MATERIALS CO., LTD.) was applied to 0.15 kg/mm.sup.2 on this surface 102 of the concrete specimen 100T.

[0130] After the primer 103 dried to the touch, an epoxy resin was applied as the adhesive 20 to a spread of 0.4 kg/m.sup.2. Subsequently, the reinforcing member sample S was pressed and bonded to the concrete specimen 100T. Thereafter, it was aged for a week at room temperature. The reinforcing member sample S was able to be bonded very well to the concrete specimen 100T without any voids occurring in the attached surface of the reinforcing member sample S.

[0131] In Comparative Example 3, the reinforcing member sample S was bonded to the concrete specimen 100T according to a conventional method. That is, as described above, in Comparative Example 3, the reinforcing member sample S was merely the FRP plate 11, and the FRP plate 11 was bonded with an adhesive directly to the concrete specimen 100T not having the high-elongation elastic resin applied thereto.

Experimental Results and Discussion

Strain Distribution

[0132] The respective strain distributions of the reinforcing member samples S in the concrete specimens 100 when a maximum load was applied are each shown in FIG. 11. In addition, Comparative Example 3 shown by the dashed line, as described above, is an example of a strain distribution graph of a specimen not having a polyurea resin (1HTN) according to a conventional method.

[0133] Comparison between these specimens has showed that the specimens having the intermediate resin layer shown in Experimental Examples 1, 2 increase in maximum load as compared with the specimens not having the intermediate resin layer shown in Comparative Examples 1, 2. In addition, both of these specimens assume a substantially-uniform strained state up to around 300 mm from the center, and thereafter decrease in strain with the distance gradually. That is, it has been found that the cases where the specimen having the intermediate resin layer according to the present invention was used (Experimental Examples 1, 2) are superior in load bearing capacity to the cases where the specimen not having the intermediate resin layer was used (Comparative Examples 1, 2).

[0134] In addition, comparison with the specimen not having a polyurea resin (the high-elongation elastic resin layer 12) according to a conventional method (Comparative Example 3) has confirmed that, in the specimens according to the laminate material bonding method of the present invention (Experimental Examples 1, 2), since the strain distributed over the whole FRP plate, stress concentration is relaxed by the polyurea resin (the high-elongation elastic resin layer 12), and the maximum strain also increases by about 2 to 2.5 times as compared with the specimen not having a polyurea resin (the high-elongation elastic resin layer 12) (Comparative Example 3), so that the adhesion performance was improved.

Maximum Load

[0135] Table 5 shows a maximum load Pmax, a maximum shearing unit stress max, an interfacial debonding failure energy Gf and a failure mode of each specimen (reinforcing member sample S). In addition, FIG. 12 shows comparison of maximum loads in the experiment of each specimen (reinforcing member sample S).

[0136] It should be noted that the maximum shearing unit stress max and the interfacial debonding failure energy Gf were calculated using Formulae (1), (2) below.

[00001]$\begin{array}{cc}\left[\mathrm{Mathematical}.Math..Math.1\right].Math.& \\ {}_{\max }=\frac{P_{\max }}{2.Math..Math.\mathrm{bl}}& \left(1\right)\\ G_f=\frac{{\left(P_{\max }\right)}^2}{8.Math..Math.b^2.Math.E_p.Math.t}& \left(2\right)\end{array}$

[0137] where

[0138] Pmax: Maximum Load (kN)

[0139] b: Reinforcing Member Sample Width (mm)

[0140] Ep: Elastic Modulus of Reinforcing Member Sample (N/mm.sup.2)

[0141] t: Thickness of Reinforcing Member Sample (mm)

[0142] l: Adhesion Length (mm)

[0143] It should be noted that, in the present experiment, the reinforcing member sample width (b) is a width (W11) in FIG. 6 and is 50 mm, the thickness (t) is a thickness (T11) and is 1 mm, and the adhesion length (l) is a reinforcing member sample length (namely a length L11) of 1200 mm. In addition, the elastic modulus (N/mm.sup.2) of the reinforcing member sample S is 167000 (N/mm.sup.2), as described above.

[0144] Table 5 shows that, in the laminate material bonding method using the specimen using the laminate material for reinforcement 10 having the intermediate resin layer 13 according to the present invention (Experimental Examples 1, 2), the maximum load Pmax is 128 kN, the maximum shearing unit stress max is 2.17 N/mm.sup.2, and the interfacial debonding failure energy Gf is 4.93 N/mm. On the other hand, when the specimen not having the intermediate resin layer 13 in the laminate material for reinforcement 10 is used (Comparative Examples 1, 2), the maximum load Pmax was 108 kN, the maximum shearing unit stress rmax was 1.83 N/Nmm.sup.2, and the interfacial debonding failure energy Gf was 3.50 N/mm.

[0145] That is, according to the laminate material bonding method of the present invention, each value increases by 1.2 to 1.4 times by forming the intermediate resin layer 13 between the FRP plate 11 and the high-elongation elastic resin layer 12, so that the effectiveness of providing the intermediate resin layer 13 in the laminate material for reinforcement 10 have been confirmed. In addition, when comparing with the specimen not having a polyurea resin according to a conventional method (Comparative Example 3), the maximum shearing unit stress max increases by 1.7 to 2 times, and the interfacial debonding failure energy Gf increases by 2.7 to 3.8 times, so that the effectiveness of a polyurea resin (the high-elongation elastic resin layer 12) in the laminate material bonding method of the present invention has been confirmed.

[0146] In this manner, it has been proved that, using the laminate material for reinforcement, the reinforcing method, and the reinforcing structural body according to the present invention, the structure 100 can be reinforced effectively.

REFERENCE SIGNS LIST

[0147] 1 Fiber sheet [0148] 10 Laminate material for reinforcement [0149] 11 Fiber-reinforced composite member [0150] 12 High-elongation elastic resin layer [0151] 13 Intermediate resin layer [0152] 14 Primer layer [0153] 20 Adhesive [0154] 100 Structure [0155] 200 Reinforcing structural body