Wrapped composite joints have emerged as a compelling alternative to traditional welding methods for fabricating steel circular hollow section (CHS) joints. These joints are distinguished by their superior performance in ultimate strength and fatigue resistance. This paper presents research on the interfacial properties and fracture mechanisms between fiber-reinforced polymer (FRP) and steel elements within these innovative joints. Given the large-scale dimensions of the wrapped composite joints in practical engineering, the study further explores the impact of size on their interfacial behavior. To this end, FRP–steel interface specimens were fabricated at three different scales. These specimens were subjected to double cantilever beam (DCB) and four-point end notched flexure (4ENF) testing, enabling the analysis of Mode I (opening) and Mode II (in-plane shear) interfacial behaviors. Additionally, finite-element analysis (FEA) was employed to further validate the interfacial properties and fracture characterization. The outcomes from this research provide critical insights into the FRP–steel interface in these innovative joints, which is essential for their accurate modeling and design. This understanding of the interfacial properties is key to the effective implementation and scalability of wrapped composite joints in real-world engineering projects.@en

This work focuses on investigating the effect of short-term changes of temperature on the mode I and mode II glass fibers woven composite interleaved with layers of chopped strand mat (CSM). Existing experimental and numerical methods are critically applied to characterize and model the delamination of the woven-CSM composite laminate. Double cantilever beam (DCB) and end notched flexure (ENF) tests are performed in non-post cured and post cured specimens at room temperature (21 °C), and the operational conditions are investigated on post cured specimens tested in low (−10 °C) and high (70 °C) temperatures. The fracture behavior is characterized using the compliance-based beam method (CBBM) while crack length estimations based on the specimen compliance are compared to direct measurements from digital image correlation (DIC). Then, a failure analysis was performed using an optical profilometer and scanning electron microscopy (SEM). Temperature changes affected the preferential crack path for the woven composite delamination in mode I loading conditions. However, the crack path in mode II fracture remained independent of the testing temperature. Fractography results revealed temperature-dependent failure mechanisms, with an increase of fiber/matrix interface debonding and matrix deformation in higher temperatures. The higher matrix ductility translated into an improvement of the delamination fracture toughness in both mode I and mode II loading conditions. Finally, non-linear cohesive models directly derived from experimental results were capable to accurately reproduce the mode I and mode II delamination fracture behavior of the woven-CSM composite in different temperatures.

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Offshore renewable energy sources, such as wind and solar require resilient support structures that are vastly loaded by cyclic loading due to wind and waves. As such, the structures built from steel circular hollow sections are structurally optimal to resist extreme loads but their design is hampered by low fatigue resistance of traditionally welded joints resulting in short lifetime, excessive use of steel material and corrosion problems. Innovative wrapped composite joints connect steel tubes by bonding and replace traditional complex welded joints of tubes by relying on excellent corrosion and fatigue performance of fibre-polymer composite material. Composite joints can reduce amount of steel needed to build supporting structures prone to fatigue up to 50% and can speed up production and assembly of towers supporting wind turbines by factor of 2. In addition, the wrapped composite joints unleash the potential of designing and building corrosion free offshore support structures completely made of composite tubes as structural members, or in combination with steel tubes. This paper presents potential of wrapped composite joints, state of development through experimental testing and numerical modelling, certification of joints and pilot projects in offshore environment. The outlook for further research and development is also given.@en

The progression of predictive models for crack propagation in fibre-reinforced polymer composites requires the quantification of crack development induced by both static and cyclic loading. The challenge of precisely measuring crack propagation becomes more intensified when cracks are not externally visible, such as in the case of delamination crack progression in thick composites. Traditional techniques, like 3D digital image correlation (3D DIC), can be employed to detect relative changes in strain distribution at the surface. However, these methods may prove insufficient, particularly for composite components with thicknesses ranging from 10mm to 100mm. Distributed optical fibre sensing emerges as a solution, enabling precise spatial measurement of strain along the fibre's length with a remarkable resolution of 0.65mm. Embedding fibres strategically in the composite during production allows measurements in close proximity to the crack surface. Placing fibres in the direction of crack growth facilitates the observation of changes in strain distribution, markedly enhancing the precision in quantifying the delaminated area compared to conventional surface monitoring methods. This investigation offers a comprehensive overview of the design, implementation, and experimental application in simple joint geometries. It places specific emphasis on large steel-glass fibre polymer composite bonded joints, commonly referred to as wrapped composite joints. The technique is initially applied to a straightforward wrapped splice joint with 1D crack propagation. The experimental results robustly affirm the effectiveness of the proposed monitoring system and postprocessing methods subjected to both static and cyclic loading conditions. The system and methods effectively quantify the propagation of debonding cracks. In summary, these findings underscore the achievability of accurately quantifying delamination crack propagation by embedding distributed optical fibres in thick composites. This study contributes valuable insights for the development of predictive models and strongly reinforces the practical significance of employing distributed optical fibre sensing in crack monitoring.@en

The integration of Glass Fibre-Polymer composite (a.k.a. GFRP) deck panels in bridge infrastructure is hindered by lacking a robust connection technology. A promising bolted connection, utilising injected steel reinforced resin (iSRR) material, has demonstrated lower creep deformation and sustained significantly more shear load cycles than conventional bolts. Nonetheless, the production and testing conditions in all prior experimental campaigns followed idealized lab set-ups. This study bridges the gap between laboratory conditions and the challenges arising during connector's fabrication under representative conditions, coupled with cyclic load testing at room and elevated temperatures. The iSRR connectors design is modified and tested in actual composite sandwich web core panels, revealing excellent fatigue performance. The statistical analysis yielded F-N curves for shear performance of the connectors that can be used in the design. The slopes of the F-N curves of − 6.6 and − 5.8 were found at room and elevated temperatures, respectively. Finally, with post-cyclic static tests displaying significant connectors’ residual stiffness, resistance, and ductility, the research provides a step forward in enabling the integration of glass fibre composite deck in infrastructure.

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Debonding is one of the most critical failure modes for bonded joints under fatigue loads. Numerical prediction on the fatigue debonding behaviour of bonded interfaces with complex geometry still remains a problem. This paper proposes a numerical methodology based on fracture mechanics to predict crack growth in a complex bi-material interface and illustrates the prediction procedure by a case study on wrapped composite joints. Interface coupon tests provide the fatigue crack growth properties at the composite-to-steel interface used as inputs for finite element (FE) modelling. The FE model is calibrated against fatigue tests of small scale wrapped composite joints with different steel surface roughness subject to different load levels. A sensitivity analysis is conducted to investigate the influence of key modelling parameters. The calibrated model is validated against fatigue tests on upscaled joints. Good agreements are shown between the test and modelling results in terms of crack growth and stiffness degradation, demonstrating the potential of the proposed numerical methodology for predicting fatigue debonding behaviour of complex bi-material interfaces.

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The dominant failure mode was characterized as debonding in the novel non-welded wrapped composite joint made with GFRP composites wrapped around steel sections. Glass fiber composite-steel three-point end notched flexure (3ENF) and four-point end notched flexure (4ENF) specimens were utilized to experimentally investigate mode II fracture behavior of this composite-steel bonded interface. Two new methods were proposed with the help of digital image correlation (DIC) technique to quantify fracture data during the tests: 1) the “shear strain scaling method” to quantify the crack length a; 2) the asymptotic analysis method based on the longitudinal displacement distribution along the height of the specimen at the pre-crack tip to quantify the crack tip opening displacement (CTOD). To numerically simulate the mode II fracture behavior, a four-linear traction-separation law was proposed in the cohesive zone modeling (CZM) where the softening behavior with a plateau was defined by the authors between traditionally considered initiation and fiber bridging behavior. The experimental and numerical approaches were validated mutually through good matches between the test and FEA results. 3ENF test provided good insight into softening behavior while 4ENF contributed to quantification of fiber bridging. These findings contribute to a more comprehensive characterization and understanding of the ductile fracture behavior of bi-material bonded joints, especially in mode II failure scenarios.

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A new technology of composite wrapped joints emerges as a promising solution for improving the longterm performance of connections between circular hollow sections (CHS). The use of composite materials is shown to improve the fatigue life of structures. However, a major challenge to the implementation of this technology is to ensure the long-term performance of the composite materials subjected to the operational conditions. This work aims to evaluate the effects of temperature changes on the fatigue delamination of a glass fiber reinforced polymer (GFRP) for application in offshore structures. Specimens were manufactured by hand lay-up and series of experiments are performed to access delamination fatigue crack growth behavior in a range of operational temperatures: -10, 21 and 70 °C. Displacement controlled end-notched flexure (ENF) tests were applied to measure the fatigue behavior together with a digital image correlation (DIC) system to monitor the displacements during the tests. Results show that the delamination fatigue performance of the composite material is not significantly affected by the range of tested temperatures. The fracture behavior also remained unchanged. Standard ENF test method has limited range of crack growth to evaluate the fatigue behavior of composite laminates.@en

Debonding is characterized as the governing failure mode in the innovative wrapped composite joints made with glass fiber composite material wrapped around steel hollow sections without welding. The prerequisite for predicting debonding failure of wrapped composite joints is to obtain fracture behavior of the composite-steel bonded interface. The mode I fracture behavior of the bonded interface was experimentally investigated using glass fiber composite-steel double cantilever beam (DCB) specimens. The crack length a and the crack tip opening displacement (CTOD) during the test were accurately measured by analyzing the digital image correlation (DIC) data while the strain energy release rate (SERR) was calculated through the extended global method (EGM). The cohesive zone modeling (CZM) was utilized in the finite element model with the proposal of a four-linear traction-separation law to simulate the mode I fracture process. An approach is introduced to determine the critical stages of the proposed four-linear cohesive law by combining accurate measurements of crack length a and CTOD, along with SERR values. The validity of the four-linear cohesive law and the introduced approach to determine the critical stages were confirmed by good agreement in both global and local behavior between the testing and the FEA results.

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The dominant failure mode in the non-welded wrapped composite joints made with GFRP composite material wrapped around steel circular hollow sections (CHS) is characterized as interface debonding. However, in the ultimate load joint experiments, debonding process was merely inferred from the surface strain distribution obtained by the digital image correlation (DIC). A thorough understanding and explicit illustration of debonding mechanism in wrapped composite X-joints is needed with help of finite element modeling (FEM), in order to provide prediction models for design of wrapped composite joints in engineering structures. In this paper, two FE models were developed to simulate the debonding behavior of small-scale and medium-scale wrapped composite 45° X-joints in monotonic tensile tests previously conducted by the authors. A new strategy of modeling complex composite geometry using 4-node tetrahedral elements (C3D4) without defining composite lay-up was proposed. The cohesive zone modeling (CZM) approach was utilized to simulate the debonding behavior of composite-steel interface with introduction of a new four-linear traction-separation law. The generated FE models were validated by good agreement between numerical and experimental results in terms of load-displacement response and surface strain distribution throughout the failure process at two joint scales. The validated models gained good insight into the joint debonding mechanism and determined the surface strain threshold for quantifying the debonding length. Development and validation of the FE models with unique set of parameters aligned well with the experiment results at two different scales is an important step for prediction and design of wrapped composite joints.

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The presented research aims to examine local fatigue failure modes of Glass Fiber-polymer Composite (a.k.a. GFRP), particularly how the bending of the Web-to-Flange Junctions (WFJ) and tensile loading of the material affects the composite's fatigue resistance. By conducting experimental analyses, the study investigates GFRP's efficacy both as a material and as a component element, drawing parallels with Eurocode standards for steel and concrete. The coupon tests under static and fatigue loading conditions provided an empirical data on the Ultimate Limit State (ULS) and fatigue resistance of the GFRP composites, including a better understanding of the effects of variation in the facing’s thicknesses in the web-core composite on the fatigue response. Subsequent three-point bending tests on the WFJ provided the insights into the strength of WFJ with the first indications on the governing failure mechanisms in the WFJ.@en

In this paper, mode II fatigue crack growth properties of the composite-to-steel interface are characterised through different test configurations, namely ENF and 4ENF tests. Different loading types including force control and displacement control methods are compared. An innovative shear strain based method is proposed for monitoring the mode II crack growth at the bi-material interface through Digital Image Correlation (DIC). A 3D finite element model with Virtual Crack Closure Technique (VCCT) is built and used for obtaining the strain energy release rate (SERR) to investigate the effect of geometrical nonlinearity, friction at the interface and steel yielding, as well as to verify the mode mixity. The results show that the standard 3-point bending ENF specimen can be unstable under force control and sweeps narrow SERR range by a single test under displacement control. The 4-point bending 4ENF test shows stable crack propagation and clear SERR developing trend. More pronounced geometrical nonlinearity and friction effect exist for 4ENF test which can be considered when interpreting the Paris curves by a nonlinear finite element model.

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Hybrid bi-material concepts in engineering structures where fibre-polymer composites are used together with steel structural members have potential to reduce material usage, extend fatigue life and improve structural reliability. The bond performance of the bi-material composite-to-steel interface is of crucial importance and highly relies on the surface preparation quality of the steel element. This paper investigates the influence of steel surface roughness on the mode II fracture toughness and fatigue crack growth behaviour of the bonded composite-to-steel joints. Glass fibre composite and mild structural steel material is considered directly bonded in a wet lay-up process. 4-point end notch flexure (4ENF) tests are conducted on specimens with the steel plates prepared with low, medium and high roughness, respectively. In addition, morphology of the fracture surfaces are characterised by a 3D profilemeter and the friction coefficient is measured by a tribometer for each roughness level. Results show that in quasi-static fracture, fibre bridging is dependent on the surface roughness. A roughness level with S_q ≥ 22 µm of the steel surface can promote significant fibre bridging thus improved fracture toughness due to enlarged effective bonding area. Under cyclic loading, no fiber bridging is observed across all roughness levels tested. However, the Paris curve parameter C is significantly affected by the roughness level, which decreases by approximately 100 times as the steel surface roughness increases from the low level of S_q = 5 µm to high level of S_q = 22 µm. The m parameter of the Paris curve remains fairly constant across all the roughness levels tested.

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Resins are essential structural materials predominantly used in load-bearing connections such as adhesively bonded joints and resin-injected bolted connections. In an effort to improve the latter, a new injection material, Steel Reinforced Resin (SRR), has been developed, consisting of spherical steel particles embedded in a resin. SRR's applicability has been explored in injection bolts used in composite steel-to-concrete floor systems and as an injection material in Fibre Reinforced Polymer (FRP) sandwich web-core panels of highway bridges. While the short-term and creep performance of SRR has been researched, its fatigue behaviour remains unexplored. From joint-level cyclic experiments with SRR, it was observed that joint endurance is dominated by SRR's fatigue performance. There is currently no research on the influence of temperature on SRR's mechanical properties and moisture uptake. This paper fills this gap, by investigating the static and fatigue performance of epoxy, unsaturated polyester polyurethane hybrid (UPE + PU), and vinyl ester based SRRs under ambient and elevated temperatures. Water absorption assessments were conducted on the three resins with and without steel particles to evaluate their durability and corrosion resistance. The results show that temperature significantly impacts tensile stiffness, tensile splitting strength, and fatigue life. Epoxy based SRR endured 20 times more tensile splitting stress cycles to failure compared to the UPE + PU resin based SRR at the same stress range. However, after 200 days of water exposure at maximum temperature, the epoxy resin (with and without steel shot) exhibited a weight increase of 4.0% and 0.50% respectively, suggesting that despite its superior fatigue performance, it may not be suitable for SRR applications in high moisture environments. In contrast, UPE + PU resin and its corresponding SRR displayed substantially lower water absorption.

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This paper presents an experimental procedure for obtaining the fracture resistance (R curve) of solid wood specimens made of spruce. Double Cantilever Beam (DCB) tests were performed in order to determine energy release rate vs crack length in Mode I wood fracture (crack opening). Ten wood specimens were loaded using the Universal Testing Machine and force-displacement curves were recorded. The most important parameter - crack length was monitored as the crack propagates using Digital Image Correlation (DIC) method. In order to obtain accurate R curve results, procedure which includes calculating cumulative released energy was employed. The cohesive energy Gf was determined based on the R curves. These results can further be analysed in order to obtain cohesive law for Mode I fracture of wood.

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Due to the low weight and excellent durability of composite materials, Fibre Reinforced Polymer (FRP) decks mounted on steel superstructures are becoming increasingly common in engineering practice. Bolted joints are generally used to facilitate connections between an FRP deck and steel girders in road bridges. The connections are subjected to both high magnitude static forces as well as fatigue loading due to overpassing vehicles. With ever increasing traffic on both road and railway bridges, fatigue performance is of critical concern. Bolted FRP joints have been extensively researched in the past under static loading, but less is known about the fatigue and creep behaviour of such joints. Furthermore, little research exists on non-pultruded FRP profiles connected using bolted connections. Therefore, the objective of this research is to investigate connectors’ feasibility by means of static, fatigue and creep experiments on four different types of bolted joints comprising mechanical connectors and injection techniques. The study focuses on application in vacuum infused GFRP panels with integrated webs made of multi-directional laminates) connected to steel bridge superstructures. In addition, experimental results are used to validate Finite Element Analyses (FEA). Based on the obtained results, the novel injected steel-reinforced resin (iSRR) connector shows promising potential in hybrid steel-FRP bridges where good fatigue endurance of the connection, are required.

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The concept of an innovative bonded joining technology where welding is not required is presented as an alternative to traditional welded connection for steel circular hollow section (CHS). Wrapped composite joints have potential to greatly improve fatigue endurance when applied in multi-membered truss structures, e.g. offshore jackets for wind turbines. This paper focuses on characterization of influence of chemical bonding resistance, fracture toughness of resins, and steel yielding on debonding of wrapped composite joints. Uniaxial splice joints (A-joints) are made with GFRP composite material wrapped around steel sections, and tested under static tensile loading conditions until failure. Different chemical bonding properties by application of bonding primer, different types of polymer resins and steel grade are used during the wrapping procedure. Debonding on the bonded interface are identified by surface strain measurements through 3D digital image correlation (DIC) technique. Testing results indicate that steel yielding limits full utilization of the resistance of the bonded interface. Wrapped composite A-joints with high-strength steel exhibits 75% larger ultimate load where yielding is prevented. Larger fracture toughness of toughened vinyl-ester resin contributes to 30% larger displacement of the joints at failure compared to regular vinyl-ester and polyester resins.

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In this paper an efficient procedure for obtaining a cohesive law for Mode I timber fracture (crack opening), based on the Double Cantilever Beam (DCB) tests is given. DCB tests were performed on ten European spruce specimens in order to determine the energy release rate vs crack length (R curves). Two crucial parameters - crack length during the experiment and the crack tip opening displacement were obtained using 2D Digital Image Correlation (DIC) technique. In order to determine accurate fracture resistance (R curve), procedure which includes calculating cumulative released energy was employed. The cohesive law for Mode I fracture of wood was obtained by differentiation of the strain energy release rate as a function of the crack tip opening displacement. This cohesive law is further implemented in the successful numerical modelling of failure modes in large-scale end-notched glulam beams which were experimentally tested in four-point bending configuration.

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Debonding crack propagation at the composite-to-steel interface has been found to be an important failure mechanism for wrapped composite joints under static and fatigue loads. Friction at the interface behind the crack tip may deviate fatigue debonding of the joints from the linear-fracture-mechanics behaviour. This paper presents static and fatigue tests of axial wrapped composite joints. 3D DIC and optical fiber system is employed to monitor displacements and crack propagation. A finite element model is established and validated against static and fatigue test results, where friction is considered at the cracked interface. Through FE modelling, it is proved that the friction at the interface significantly reduce the strain energy release rate (SERR) at the crack tip, leading to retardations of crack growth and stiffness degradation. Parametric study is conducted finally to investigate the influence of friction coefficient, failure modes as well as Paris relationship parameters on the predicted fatigue behaviour of wrapped composite joints.

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In response to the sustainability requirements set in the EU Commission´s “Green Deal” towards reduction of the greenhouse gas emissions, it is estimated that the structural design for deconstruction is going to contribute considerably to the sustainable development of the built environment. The demountability of multi-material structural systems basically depends on the shear connectors used in the structural system. This paper focuses on a type of demountable injected shear connector with an injected steel-reinforced resin (iSRR) which consists of spherical steel particles embedded in a resin. Its application to steel-to-concrete and steel-to-Fiber Reinforced Polymer (FRP) decks is presented along with its benefits. In parallel, an overview of the experimental and numerical research on the evaluation of the mechanical properties of the demountable bolted connectors with iSRR is discussed. Last, detailed finite element (FE) models and a parametric study are performed to quantify the confinement level of the SRR material influenced by the oversized hole diameter.

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