Flyover In Western India Flyover In Western India

Site Background

Over a 50 years old flyover in western India was retrofitted using the Reliance Carbon Fiber Reinforce Polymer - CFRP solutions. 36 expansion joints in the flyover was replaced and the load barring capacity was improved using the provided CFRP Solution.

Solution Provided

The Carbon fiber wrapping Solution provided for this site was:

  • Application of 4 layers of carbon fiber on the bottom phase of the girder along the length of the beam.
  • Application 1 layer of carbon fiber as U wrap till 1/3rd of the length of the span from both the ends of the girder.

Timeline for Completion of Work

18-24 Months (Including Surface Preparation to Final Wrapping process)

Materials Used

  • RELINFORCETM C Fab 600
  • RELINFORCETM EP Putty
  • RELINFORCETM Fab S

Application Process

  • As being a very old bridge, micro-concreting work was done and all undulations were filled using the RELINFORCETM EP Putty to provide a smooth surface was made ready for CFRP application.
  • Reliance RELINFORCETM provides a primer less system for CFRP wrapping solution on concrete structures.
  • Once surface preparation was done, RELINFORCETM C Fab 600 was then applied to the girders, beams and pillars with the help of RELINFORCETM Fab S as per the provided consumption.
  • As per the site requirements we have applied 4 layers of Carbon fiber along the length of the beam.
  • After the installation of 4 horizontal carbon fiber layers, U Wrapping process was started. Theses 4 layers wrapping majorly provides the strength and support to the beam as well as to the structure.
  • U wrapping process provides holding support to the applied 4 layers of the carbon fabric which further improves the strength of the structure.
  • This CFRP wrapped fabric was then again painted with Epoxy & PU based coating to avoid the environmental degradation of the Epoxy saturant as well as to give better aesthetics to the flyover.

Benefits of Using RELINFORCETM Carbon Fabric in Flyover Project

  • RELINFORCETM provided faster repair than conventional methods and do not require any hot work like welding.
  • The whole wrapping process of whole bridge was completed in 12-18 months because of the easy application.
  • The Flyover was operational during the whole repair work process. No road blockage was required during the retrofitting work which is generally not the case if we use the conventional repair methods.
  • Minimal change to structure’s weight was observed.

Surface Preparation

Application of CFRP Strengthening System

Application of Saturant Layer for U Wrapping

Impregnation of C Fabric with the Saturant

U Wrapped Beam