Integrated Trans-IND system
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Trans-IND integrated process
It is well-known that the construction sector is a very traditional one and that every innovation needs an
period for acceptance by the end users. Introducing Fiber Reinforced Materials (FRP) in this sector is
difficult because the construction process has been optimized for traditional materials (concrete and
steel) that are popular within this sector. In order to introduce FRP materials in this sector, this new and
advanced material has to gain trust among the people (technical, commercial, architects, etc.) and this
will only be possible when they are supported by a design code accepted by the standardization bodies.
The integrated Trans-IND system not only deals with FRP, manufacturing components made of FRP,
their assembly, but it also goes further. The integrated Trans-IND system tries to optimize the
management of the whole construction site from its beginning at the tender stage to its maintenance
and demolition. It will be shown that Information and Communication Technologies (ICTs) are very
important in this system, and introducing these technologies into the construction sector will also be a
challenge, where traditional methods are very difficult to substitute.
A scheme (see Figure 2 below) has been prepared in order to show the philosophy of this integrated
system with an emphasis on the valid results.
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Integrated Trans-IND system
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Figure 2: Influence of the Integrated Trans-IND system on the traditional construction process of transport infrastructure
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Integrated Trans-IND system
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Technical solutions of Integrated Trans-IND system
Overview and list of the solutions
In order to give a better overview of the works that have been performed within the Trans-IND project,
the list of specific technical solutions and guidelines was created, Table 1. Each solution is assigned to
a different phase of the construction process and described in details.
Table 1 List of technical solutions within Trans-IND project.
Implementation phase
Solutions
Design
Design of FRP beams
FRP deck system
Safety barrier system
Acoustic barrier system
Plug-in joint solutions
Catalogue of standardised FRP components
Manufacturing process
Off-site industrialization process
Autonomous navigation system for beam finishing operations
Epoxy resin application into the manufacturing system for Trans-IND
components
Lab-scale modular system for fabrication of composite components (closed
shape beam) including software control system
Multi-axial UD Crossply machine (material manufacturing process)
FRP deck manufacturing process
Automation of cross-ply process for DForm® prepreg production
Rib mold manufacturing including DForm® technology (Deformable Composite
System)
Continuous Compression Molding process
Automatic Quality Control and NDT procedures
Support for optimized design of dimensional and morphological control system
for FRP components using laser scanner technology
Logistics & Assembly process
Conceptual on-site assembly method
RFID-based technologies supporting logistics and assembly process
Asset management tool for the on-site assembly process
QRCodes tool for item tracking and production and assembly support
Trans-IND scheduler
Intelligent position system based on 3D technology to assist crane movement
All phases of construction process Business model for value chain integration
Bridge semantic model and rules
Testing and certification procedures
Recommendation for standardisation
Integrated Trans-IND system
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Integrated Trans-IND system
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The project intends to deliver integrated package of solutions and techniques that enable to construct a
transport infrastructure in a more efficient way. The Trans-IND system contributes with specific solutions
to different stages of the construction process from the design to the maintenance of the structure,
Figure 9. Only in this way the Integrated system can be obtained and successfully implemented on the
market.
Figure 9: Components of the Integrated Trans-IND system
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Integrated Trans-IND system
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Design phase
The solutions for the design phase covers innovative bridge components, Figure 10:
– structural parts: deck, beams and plug-in joint system,
–
secondary elements: Acoustic and safety barriers.
Figure 10: Trans-IND bridge system
In order to facilitate the work of the architects and civil engineers, a special catalogue with the design
bridge components has been prepared. The catalogue includes design models and gives detailed
information about element typology, material, dimensions, span, durability and resistance. The paper
shows how to integrate the components into the day-to-day design process of transport infrastructure.
The catalogue is divided into four chapters: Introduction (History and advantages of use of FRPs),
Structural elements (Beams, Decks, Joints), Secondary elements (Acoustic and Safety barriers) and
short info about the Trans-IND project.
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Integrated Trans-IND system
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FRP beams
Description
Three types of FRP beams have been designed in order to cover a wide range of combinations of
load and span made of polymer composite materials (FRP). The range covered for load and span is
from 5 to 9 kN/m2 and from 10 to 40 m respectively.
Scheme
Figure 11: Open-shaped FRP beam
Figure 12: Close-shaped FRP beam
Figure 13: U-shaped FRP beam
Innovativeness
Actors of construction process
FRP beams will provide an alternative solution to the existing modular beams made in traditional
materials, adding all the advantages of these polymer composite materials, FRP (better reaction to
corrosion, long life cycle, lightness, good mechanical properties, etc.).
Designer, Structural Engineering, Cost Engineer, Main Contractor, Project Manager
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Integrated Trans-IND system
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FRP deck system
Description
FRP composite bridge deck is a solution for refurbishment of the existing bridges and construction of
new ones. FRP deck system can be applied to different types of composite beams: open-shaped beam,
close-shaped beam and U-shaped beam. The basic materials for the deck are: glass fibre, epoxy resin
and concrete. The depth of the deck is 0,35 cm (including concrete slab) and the ideal span varies
between 2-3 m.
Scheme
Figure 14: Scheme of FRP deck system
Figure 15: Scheme of FRP deck system installed on FRP beams
Innovativeness
Actors of construction
process
FRP deck system brings the advantages of the composite materials. The benefits of solutions are:
durability, light weight, high strength, rapid installation, lower or competitive life-cycle cost, high quality
manufacturing process under controlled environments, long service life.
Designer, Structural Engineering, Cost Engineer, Main Contractor, Project Manager
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Integrated Trans-IND system
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Safety barrier system
Description
Two typologies of safety barriers have been developed in Trans-IND project, according to the European
Standards EN 1317-2: simple safety barriers and safety barriers with foam.
Both types of Trans-IND safety barriers have the same geometrical dimensions and consist of the same
main elements: two closed cap FRP profiles (single and double) supported by steel posts. The only
difference is the foam within the closed cap profiles.
A detailed description of the elements and the materials that compose the safety barrier are shown on
Figure 16 and 17.
Scheme
Figure 16 Scheme of the safety barrier
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Integrated Trans-IND system
Figure 17: Cross-section of the safety barrier
The use of closed cap profiles in FRP supported by posts in traditional material is a new solution in the
field of the safety barriers, usually made of steel elements. The innovation is based on the following
concept: the FRP profiles provide the needed resistance to a potential impact and the support in steel
profiles ensure the necessary ductility to the barrier, according to the European Standards (EN1317-2).
Innovativeness
Actors
process
of
Page 9 of 37
construction
Designer, Structural Engineering, Cost Engineer, Main Contractor, Project Manager, Supplier, off-site
manufacturer
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Integrated Trans-IND system
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Acoustic barrier system
Description
The acoustic barrier system covers five configurations of the barriers. Based on the performance regarding the
efficiency of five designs of acoustic barriers using advance composite materials (GFRP) it was concluded that
the most interesting, innovative, and most effective design, is the option #5, which consisted of a sandwich of
two layers of rock wool between two veils of polyvinyl alcohol nano-particles and an exterior cover of a plane
and a curved layer of GFRP. Although the most suitable acoustic barrier is option #1, from an economical point
of view, if aesthetic and environmental factors are considered, the best option is clearly option #3.
Scheme
Figure 18: Different configuration of acoustic barriers
Innovativeness
Actors of construction
process
Figure 19: On the left detail of the simple acoustic barrier design (option #1), on the right detail of the
curved acoustic barrier design (option #5)
The results obtained regarding the efficiency of the acoustic barriers with composite revealed a significant
increase in the noise reduction index when GFRP is included in all the designs developed. The best results in
this sense were obtained for design #5, the curved acoustic barrier. This increment in the efficiency combined
with an innovative design (both options #3 and #5) makes this system an attractive option for future acoustic
barriers in the transport infrastructure.
Designer, Structural Engineering, Cost Engineer, Main Contractor, Project Manager, Supplier, off-site
manufacturer
10
Integrated Trans-IND system
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Plug-in joint solutions
Description
Three types of structural joints between the beams and the deck have been designed and tested.
The open-shape (U and V) beams are connected to the FRP deck through shear rods. These
connectors are placed and glued in holes previously drilled on the upper flange of the FRP beams.
The close-shape beams are connected to the FRP deck through T shape steel plates (Perfobond)
or steel sheeting glued to the top surface of the beam. Transverse reinforcing bars are placed
through those metallic elements to increase their interaction with the concrete layer.
The main advantages of the solutions are:
They do not interfere in the manufacture of the beam
They are easy to install / assemble on - site
They are commercial or mass-produced items
Scheme
Innovativeness
Actors of
process
construction
Figure 20: Scheme of the joints between beam and deck
There are no standard joints for FRP structures. The proposed ones allow connection between
beams and decks in bridges and other structures. They are in line with the objectives of Trans-IND
project regarding the on-site assembly and cost reduction strategies.
The joining systems are original from the concrete-steel composite structures. They have been
redesigned under the working mode of the FRPs. The analytical estimations of the mechanical
capacities have been validated through experimental tests.
Designer, Structural Engineering, Cost Engineer, Main Contractor, Project Manager, Supplier, offsite manufacturer
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Integrated Trans-IND system
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Catalogue of standardised FRP components
Description
Trans-IND Catalogue is a collection of the main composite components developed in the Trans-IND
project for designing transport infrastructures. The Catalogue includes both structural and
secondary elements:
Beams: Open-shaped beams, Closed-shaped beams, U-shaped beams
Deck solutions for: Open-shaped beams, Close-shaped beams, U-shaped beams
Joints solutions for: Open-shaped beams, Close-shaped beams, U-shaped beams
Safety Barriers: Simple safety barriers, Safety barriers with foam
Acoustic Barriers: Simple acoustic barriers, Curved acoustic barriers, Acoustic barriers with
vegetation
Furthermore, a general overview of the main characteristics and properties of the composite
materials is specified in the introduction together with a description of the advantages of using FRP
composite materials in civil construction.
Moreover, since the Catalogue is a tool for the dissemination of the Trans-IND project results, a
final section is dedicated to a brief summary of the project objectives and an overview of the TransIND Consortium Partners.
Scheme
12
Integrated Trans-IND system
Figure 21: Catalogue of standardised Trans-IND components
The Trans-IND Catalogue makes designing easier thanks to the collection of the technical
information about the main transport infrastructures’ components, materials, standards and some
solutions to solve typical design problems.
Innovativeness
Actors of
process
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construction
Designer, Structural Engineering, Cost Engineer, Main Contractor, Project Manager,
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Integrated Trans-IND system
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Manufacturing process
An integral part of the project is the development of the automated off-site manufacturing process for
modular FRP transport infrastructure components, Figure 22. This new process is characterised by a
high automation level and at the same time is highly flexible and agile for coping with different sizes and
quantities of FRP components. It is important that the system allowed to control the flow of materials
and components and also to manage human security issues and the available human resources. Due to
the fact that the manufacturing concept is directly adapted for the FRP components and their properties,
planning, time and cost efficiency can be achieved. Integral part of the manufacturing process is the
development of the machinery for FRP transport infrastructure that utilize the process of filament
winding, pre-preg production and advanced pultrusion.
Figure 22: General concept of the overall manufacturing process
As a consequence, it can be concluded that the manufacturing system based on new systems, will be
able to significantly improve the existent methods, and bring important benefits in terms of:
- Time reduction with respect to the current manufacturing processes for equivalent FRP components,
- Labour cost reduction,
- Energy cost reduction,
- Increase competitiveness of the FRP components with respect to concrete,
- Improvement of job quality and workers satisfaction because of a safer, cleaner and easier process.
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Integrated Trans-IND system
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Off-Site Industrialisation Process
Description
Conceptual design of the off-site industrialisation process deals with the design of the planning
layout for the automated industrialisation process, and therefore the definition of the logistics and
process planning activities for the most suitable production process in terms of cost-effectiveness,
flexibility, efficiency and productivity.
The resulting process features a high automation level and at the same time is highly flexible and
agile for coping different sizes and quantities of FRP components.
These features allow the resulting system to control the flow of materials and components and also
to manage human security issues and the available human resources. Finally, energy efficiency
issues as well as RFID technological aspects are considered in this phase of conceptual design.
Scheme
Innovativeness
Actors of
process
construction
Figure 23: Off-site industrialisation concept
Manufacturing processes on a high automation level and, at the same time, high flexibility and
agility for coping with different sizes and quantities of FRP components. Adapting the
manufacturing system regarding different product types and quantities to variable market demands.
In terms of performance, this result can be seen as a specified and adopted manufacturing concept
for FRP components. Therefore it can save planning and modelling time and also costs.
Quality control officer, Main Contractor, Safety Control Officer, Procurement Officer, Supplier, offsite manufacturer
15
Integrated Trans-IND system
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Autonomous navigation system for mobile platforms
Description
An autonomous navigation system for a mobile platform has been developed and tested. It will help
to increase the automation level of the finishing operations done on composite beams or other large
structures. Once the navigation algorithms are implemented in the appropriate mobile system, the
platform can move in a safe way along the beam and can carry and position necessary equipment
for finishing operations with high precision.
The main advantages of the solution are
Beam is used as support and guiding.
Compact and autonomous system, low space required.
Flexibility in beam size within the crawler frame.
Fast deployment and quick referencing.
Scheme
Figure 24: Scheme autonomous navigation system for a mobile platform
Innovativeness
Actors of
process
construction
With the help of the developed navigation system, some of the finishing operations that nowadays
are done manually, such as drilling or sanding, could be performed automatically, assuring process
quality, and reducing the tack time of this operation.
Although these operations could also be made by traditional large machine tools, the main
advantages of the proposed solution are that the investment is lower, the system is compact and
autonomous, and it is more versatile and transportable from one side of the manufacturing floor to
another.
Quality control officer, Main Contractor, Safety Control Officer, Procurement Officer, Supplier, offsite manufacturer
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Epoxy resin application into the manufacturing system for Trans-IND components
Description
In the Trans-IND project, thermosets resins will be processed via filament winding (beam
production) and pultrusion (deck production). Those 2 processes as well as the requirements
needed for the resins when using those processes are described and suitable epoxy resin systems
are proposed.
Filament Winding:
Scheme
Pot-life (100g,
23°C) (Process)
Initial mix
viscosity
(mPa.s)
Tg (°C)
(properties)
Cure cycle
(Energy
consumption)
Araldite®LY1135-1/Aradur®
917/ Accelerator 960-1
Araldite®3585 /
Aradur® 3486
Araldite®LY 556/
Aradur ® 22962
56 - 62 h
480 - 580 min
110 - 150 min
600 - 1000
500 - 650
400 - 600
132 -138
100 - 110
130 - 140
4h/80°C + 4h/120°C
2h/100°C
15 min/120°C +
2h/150°C
Pultrusion:
Araldite® LY1135-1/ Aradur®
917/
Araldite® DY 070
95 – 115 h
Innovativeness
Actors of
process
construction
Araldite® LY 1568 /
Aradur® 917/ Araldite®
DY070
40 - 50 h
Pot-life (100g, 23°C)
(Process)
Initial mix viscosity (mPa.s)
600 – 900
500 - 700
Tg (°C) (properties)
140 -150
140-150
Cure cycle
4h/80°C + 4h/140°C
4h/80°C + 4h/140°C
(Energy consumption)
Automated lamination of large parts with the lowest cost and energy consumption possible with
having the required mechanical properties for infrastructures of bridges.
Main Contractor, Procurement Officer, Supplier, off-site manufacturer
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Integrated Trans-IND system
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Lab-scale modular system for fabrication of composite components (closed shape beam) including software
control system
Description
New automated and flexible system for producing FRP components (close-shape beam) with
combination of two technology processes: Filament winding process and Tape laying process.
Specially developed software control system based on specific requirements associated with the
structure of composite components.
Scheme
Innovativeness
Actors of
process
construction
Figure 25: System for producing FRP components
Designed equipment for production of close-shape beam has the possibility to use two
technologies, Filament Winding and ATL technology.
For both technologies, two independent software packages are prepared.
All equipment parts with specially defined delivery tools are designed in order to achieve full
automation of manufacturing process of this type of beams.
Result allows to increase productivity, reduction of time; use the different types of materials in
production process.
Main Contractor, Supplier, off-site manufacturer
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Integrated Trans-IND system
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Multiaxial Crossply Machine
Description
The Multiaxial Crossply Machine enables the reel-to-reel production of laminates consisting of two
or more UD layers with cross layers varying in orientation from 45 to 90 o. In this way both technical
textile and composite laminates can be produced efficiently from rolls of UD-material consisting of
various fibres and matrices. UDs based on thermoset - as well as thermoplastic matrix materials
can be laminated by this machine, although latter category is favourable because of its efficient
processing to building components by means of welding or thermoforming.
Scheme
Figure 26: Multiaxial Crossply Machine
Innovativeness
Actors of
process
construction
Current production processes for technical textile and composites are rather slow because they
consist of a weaving/winding and coating/impregnation step, while in case of UD & Crossply
technology, both are integrated. Besides, the option to vary the orientation of the UD layers in the
laminate in comparison with the 0/900geometry of a fabric, the reinforcement of the resulting
textile/composite can be optimized for its specific application.
Main Contractor, Supplier, off-site manufacturer
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FRP deck manufacturing process
Description
The result is an optimized manufacturing process which will allow us to manufacture deck parts, in
a continuous and, therefore, cost-effective way.
Scheme
4
1
2
3
1- Raw material storage
4- Pulling device
Innovativeness
Actors of
process
construction
5
2- Fiber impregnation
3- Pultrusion die
5- Cutting device
Figure 27: Scheme of deck manufacturing process
After studying and testing various methods for impregnating and guiding the fibres, optimized way
to get the fibres impregnated and guided for manufacturing the bridge deck was developed.
Quality control officer, Main Contractor, Safety Control Officer, Procurement Officer, Supplier, offsite manufacturer
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Integrated Trans-IND system
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Automation of cross-ply process for DForm® pre-preg production
Rapid molding with DForm allowing unidirectional pre-preg to be formed over complex shapes
including double curvatures and tight radii, this technology is established and patented but current
production methods are slow and labour-intensive; automation will significantly reduce the material
costs while improving the life of the material, this will be particularly important for low temperature
curing resin systems such as the Umeco LTM series of tooling resins.
Description
Scheme
Innovativeness
Actors of
process
construction
Figure 28: Schematic of the automated cross-plying process for DForm
The innovation in this result is the automation of a crucial stage in the manufacture of the DForm
pre-preg which requires crossplying in order to render the material practical.
Sub-contractor, Supplier, off-site manufacturer
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Integrated Trans-IND system
Description
Page 22 of 37
Rib mold manufacturing including DForm® technology (Deformable Composite System)
Rapid molding with DForm allowing unidirectional pre-preg to be formed over complex shapes
including double curvatures and tight radii; this technology will be demonstrated through the
production of a rib tool and component. Current methods include woven fabric pre-preg which is
much more labour-intensive to lay up and dry pre-form infusion which has limitations in achievable
fibre content and resin properties
Scheme
Innovativeness
Actors of
process
construction
Figure 29: CAD schematic of DForm rib tool
Previously tooling for this type of component would be manufactured using conventional woven
fabric-based pre-preg which takes much more skill and time to make a tool skin; DForm has not
previously been used in the construction sector and it is anticipated that this will show a
measurable improvement in cost effective manufacture of the tool and the components made using
the tool.
Sub-contractor, Supplier, off-site manufacturer
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Continuous Compression Molding process
Description
Continuous Compression Molding (CCM) is a semi-continuous process in which several pressing
tools are included in one press. These tools are arranged in a row and the material is transported
through them. But the use of one continuous tool is also possible. This tool is attached to only one
press and is fed with a certain amount of material. The main objective of the Continuous
Compression Molding process is to separate the heating and the cooling zone of the tool in order to
realize high heating and cooling rates. This means that the impregnation and the solidification take
place in different parts of the tool. In the heated section at the beginning the material is impregnated
and consolidated and then it is still consolidated and also solidified in the cooling section.
Scheme
Innovativeness
Actors of
process
construction
Figure 30: Scheme of Continuous Compression Molding (CCM)
Within the Trans-IND project several production trials for the manufacturing of the safety barriers by
use of continuous compression molding process were performed. The aim of this study was to
evaluate the feasibility of the production of closed cap profiles in one
single step that can be used as safety barriers afterwards. As suitable process, the continuous
compression molding process was identified.
Main Contractor, Sub-contractor, Supplier, off-site manufacturer
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Integrated Trans-IND system
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Inspections for NDT procedures
The main objective of “Automatic quality control and NDT (Non-destructive testing) procedures”
Description
is to develop and optimize dedicated techniques for the quality and integrity control of new FRP
components for Trans-IND project. Main issues like the large size, high thickness and complex shape
have been addressed.
The optimal NDT techniques and configurations for the different Trans-IND components have been
identified and described. In particular a new configuration of the ultrasonic technique has been
developed to overcome the current limit in inspecting sandwich elements with high thickness and low
density core. The system developed meets the requirements of easiness and flexibility for a further
implementation in the production site.
Scheme
Contact emitter,
ultrasound probe
Non-contact
receiver,
ultrasound probe
Figure 31: On the left NDT inspection with hybrid configuration on sandwich structure, on the
right C-Scan inspection result
Defect
Innovativeness
Actors of
process
construction
Figure 32: On the left NDT inspection with ultrasound in pulse echo mode on curved panel,
on the right C-Scan inspection result
The inspection of the structural integrity of composite components with complex shapes (high
thickness, complex profiles, sandwich structure) for civil construction and infrastructures are very
challenging for NDT at the state of the art. Moreove,r the flexibility of these solutions allow to inspect
a large area automatically. An accurate inspection reduces the risk of cracks, accident and cost of
maintenance.
Quality control officer, Quality Surveyor, Main Contractor, Sub-contractor, Supplier, off-site
manufacturer, Service Provider
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Support for optimized design of dimensional and morphological control system for FRP components using
laser scanner technology.
Description
Innovativeness
Actors of
process
construction
The quality control of FRP components is certainly an important phase of the off-site production to
guarantee the respect of the engineering specifications and tolerances.
The result is focused on the development of methods and procedures based on laser scanner
technology dedicated to design, Hw and Sw configuration and set up of the most appropriate
“dimensional and morphological control system” for the FRP products and processes. Developed
methods and procedures will be used by ITIA to provide an integrated service focused on
dimensional and morphological control.
The integrated consultancy service concerns the study, the design and the set-up of the best solution
– according to the specific set of requirements - for the dimensional and morphological control of
FRP components and it will be fully customized to customer’s needs.
An integrated service dedicated to design, configuration and set-up of the most adequate control
system is a new service that we consider innovative and unique.
Main Contractor, Sub-contractor, Supplier, off-site manufacturer, Service Provider
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Integrated Trans-IND system
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Logistics and Assembly process
The new approach to logistics and on-site assembly process enable to obtain shortened installation
process and what is important to limit traffic disturbance, that frequently provoke many problems during
construction of transport infrastructure. The flexible process that can be used in different climatic
conditions covers new technologies like: tracing the elements by RFID system and intelligent positioning
system. As a result, on just-in-time delivery of the components can be achieved, which enables
construction on the space-limited sites.
The RFID could help monitoring the structural components, equipments, tools or even staff during the
FRP bridge and its elements construction, Figure 33. It would mean an improvement in the traceability
of the process. There are two main fields in which the RFID can be used:
– Logistics: This involves mainly tracking and tracing (controlling, monitoring) and also security
and safety (theft, accident, loss of fright).
– Working site: This involves mainly tracking and tracing, resource management (human resource
management, machine management, asset management and site management), installation
through a semi-automated process (beam installation, deck panel installation, etc.), supporting
the demolition process and maintenance.
Tag
Chip
Data
Antenna
Reader
Middleware
Application
server
Figure 33: Scheme of RFID system
The role of the intelligent positioning system is to improve the positioning of large elements such as a
beam, Figure 34. The aim is to position a beam in a correct place with the highest precision possible.
Figure 34: Scheme of intelligent positioning system
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Integrated Trans-IND system
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Conceptual on-site assembly method
Result description
Conceptual on-site assembly method describes new possibilities for assembly process that are
available for the FRP infrastructure components e.g. use of light cranes and plug in joints. New
technologies like: tracing the elements by RFID system and intelligent positioning system. The goal of
the application of new technologies is to obtain shortened installation process and limit traffic
disturbance. Moreover conceptual on-site assembly focuses on just-in-time delivery, which enables
construction on space-limited sites.
Scheme
Figure 35: Scheme of intelligent positioning system
Innovativeness
Actors
process
of
construction
In comparison with traditional installation scheme, the Trans-IND method utilizes innovative solutions
that until now were successfully used in other sectors. Example of the new technologies are: tracing
the element by RFID system and intelligent positioning system that is based on 3D vision technology.
Quality control officer, Quality Surveyor, Trainer, educator, Main Contractor, Project Manager, Safety
Control Officer, Sub-contractor
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Integrated Trans-IND system
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RFID-based technologies supporting logistics and assembly process
Description
RFID-based technologies support the logistic and assembly processes by providing a contactless and correct
identification of the FRP bridge components. To satisfy the requirements made for different RFID application scenarios a
strategy was proposed regarding all relevant aspects influence the selection of certain RFID devices. Here, the starting
point for the selection process is formed by the components to be tagged, the concrete application and the environment
RFID is used. Based on these boundary conditions certain criteria can be derived allowing the analysis of RFID product
catalogues. The result of this strategy is the most appropriate RFID system (reader, transponder and middleware).
Scheme
Components
Element
Type
Beam-Element,
DeckElement,…
Individual
Elements:
Beams,
decks, ...
Conditions
Application
Case
Constr. Phase,
Maintenance
Phase,…
Selection
Process
Selection Criteria
Manuf
acturer
Tag name
functio
nality
Tag Mount
orientation
Dectag
DecTagFlex
Read/
Wirte
Horizontal
Confid
ex
Confidex
Carrier Pro
Readonly
Horizontal
GAO
Tag- Flex
N/A
optional
Frick
Foam
Backed Tag
Read/
write
Horizontal
Proposed Readers
Reader
Manufacturer
Name
Nordic ID
PL3000
Mobile
Motorola
System
Temperature,
Precipitation,…
Manufacturer Info
RFID
Tracking,
Documentation
,…
Pallets
Single Element,
Pallet,…
Application
Application
Type
RFID Product
Catalogues
Boundary Condition
Off-Site,
On-Site,
Shipment
Element
Level of
Detail
Environment
Location
Proposed Transponders
Stationary
•
•
•
•
Transponder Characteristics
Transponder Fixing Method
Reader Characteristics
Communication
Transponder/Reader/Middleware
• Economic criteria
Impinj
speedway
Alien
MC9090-G
R-220 or R420
ALR-9900
Middleware
Open source Fosstrak EPCIS Repository
Figure 36: RFID technologies for logistic and assembly
Innovativeness
Actors
of
construction
process
The proposed RFID system represents an appropriate solution for timely identification of FRP bridge components in
different application scenarios. It is flexible to apply in different construction process phases and reuse again in other
projects. It also provides information accessible to all project partners, can be extended to include other ID-technology
(Barcode, QRcode) for further applications and offers common interfaces to use the gathered data for further processing
e.g. in the intended KMT (Knowledge Management Tool).
Project Managers, Main Contractor, Quality Control Officers, Sub-Contractors, Quality Surveyors, Suppliers, Off-Site
Manufacturers ,Service Provider (logistics),Tester.
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Integrated Trans-IND system
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Asset management tool for the on-site assembly process
Description
Software functionalities included into the integrated Trans-IND software platform allow to: uniquely identify
physical bridge parts by means of RFID and/or QRCode tags; associate information to the parts:
manufacturing and test reports, handling, safety and assembly instructions; track the location of these
physical parts; providing up-to-date information of the location of the parts of a bridge; access part
information and main assembly instructions from anywhere using the identifier of the part.
Scheme
Innovativeness
Actors of
process
construction
Figure 37: Asset management tool
Parts logistics and on-site will benefit from up-to-date and remotely available information about parts,
including: exact location of parts involved in assembly steps, access to handling and mounting instructions,
access to 3D views of the parts, access to animations of the mounting steps.
This interactive information retrieval will contrast with current situation where most of it is paper-based.
Project Managers, Main Contractor, Service Provider (logistics), Tester.
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Integrated Trans-IND system
Page 30 of 37
QRCodes tool for item tracking and production and assembly support
Description
This tool for item tracking and provision of on-site information support is based on a unique QR code tag
attached to each part of a bridge, which identifies the part, allows geo-positioning of the part, and provides
on-line link to extended part and project information.
The application consists of two software modules: the Smart-phone Client and the Information Centre Web
Application, which are communicated through the Knowledge Management Tool (KMT application), which
in turn provides a set of web services facilitating full duplex part information retrieval and/or update.
The Smartphone Client allows to scan the QR coded identification of a part via the camera integrated on the
device and uses the GPS functionality available on the smart-phone for positioning the scanned item. It
also provides an interface for on-site access to graphical and textual information on part properties,
montage instructions, project specifications, quality procedures and guidelines, or any further details
available on the knowledge base, as well as real time messages created by the Information Centre
operator.
The Information Centre Web Application allows tracking of parts on a map and information exchange with
the user on-site.
Scheme
Figure 38: Scheme of the work of QRCodes tool
Innovativeness
Actors of
process
On-site crews rarely have access to the internet, but a Smartphone with a camera, internet connection and
positioning capability are becoming a standard. QR codes scanning and processing combined with
positioning and wireless networking technologies are used to develop innovative solutions which allow
architectural, engineering and construction companies to do daily on-site jobs more efficiently.
construction
Project Managers, Main Contractor, Service Provider (logistics), Tester.
30
Integrated Trans-IND system
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Trans-IND scheduler
Description
Trans-IND scheduler is a tool for planning and management of construction projects. It helps to plan the
integrated transport process and installation of bridge facility elements. The tool has easy-to-operate
graphic user interface combined with suitable description. The construction works completion schedule set
by the application can be presented in a graphic form - a Gantt chart, or in a text form - dates of
commencement/completion of particular construction works. Application of a fast algorithm approximated to
the scheduling of construction projects allows to obtain high-quality solutions (in the sense of values of the
objective function) in a short time.
Scheme
Figure 39: Trans-IND scheduler programme window
Innovativeness
Actors of
process
construction
The tools help to plan and manage the transport and installation process of the FRP bridge components.
Trans-IND project not only focus on the innovative material solution but also provides products for easier
and more efficient work scheduling.
Project Managers, Main Contractor, Service Provider (logistics), Tester
31
Integrated Trans-IND system
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Intelligent position system based on 3D technology to assist crane movement
Description
An application based on 3D vision technology that localizes and helps positioning of a beam with respect to
a target position has been developed and tested. The developed algorithms can be used with any camera
that provides a point cloud as output data. The precision obtained with the positioning system is due mainly
to the camera chosen. The application can be configured for different types of beams, by including beams
features on the system, so that it recognises the new geometry as the beam to be localised.
Scheme
Figure 40: Scheme of intelligent positioning system
Innovativeness
Actors of
process
construction
The developed application will improve the assembly procedure on site by guiding crane operator with the
help of vision technology. As a consequence, it will bring a decrease of the necessary time during assembly
operation and reduction of human resources during assembly.
Quality control officer, Project Managers, Main Contractor, Safety Control Officer, Sub-contractor
32
Integrated Trans-IND system
Page 33 of 37
Intelligent positioning system: Manual Guidance Device for on-site assembling and disassembling activities of FRP
barriers
Description
The result is focused on the development of a tool, called a manual guidance device – dedicated to intuitive
robot programming during assembly and disassembly activities, enhancing productivity.
The Manual Guidance Device (MGD) is a tool to intuitively move a manipulator. No specific skill or previous
training is needed to perform pick and place operations reducing in that way the programming effort and so
increasing assembly working time. It’s suited to guide robots dedicated to FRP barriers and small FRP
components assembly
Scheme
Innovativeness
Actors of
process
construction
Figure 41: Example of the called manual guidance device scheme
Manual Guidance (MG) technology is an innovation in itself and even more in the construction sector,
where manual work is still prevalent. The introduction of such a technology could significantly improve
productivity.
Quality control officer, Project Managers, Main Contractor, Safety Control Officer, Sub-contractor
33
Integrated Trans-IND system
Page 34 of 37
Management of the integrated construction process
The Trans-IND project delivers solutions that help to manage/administer the whole construction process
of FRP transport infrastructure. Such results can be used in different stages of the process and are
adjusted to the needs of the main actors of the process. In order to obtain innovative approach within
construction process, the existing projects, solutions from other sectors, lean manufacturing practices
were investigated and best techniques were adapted to the special features of FRP transport
infrastructure.
An important part of the Integrated Trans-IND system is a new business model to overcome the existing
market and legal barriers, especially concerning the fragmentation problem in the construction sector.
Physically, it will allow companies to create new and profitable revenue streams, and find competitive
advantage.
The new business model is geared towards the large-scale implementation of FRP in civil infrastructure
projects across the EU. Its main aspects are:
– Industrialised value-chain integration (including demand and supply chains) instead of one-off
project strategy,
– Performance-based instead of lowest-price procurement.
The new business model is built upon the knowledge of: current and future market potentials;
characteristics of the current business models; innovative asset management concept; and feasibility
analysis supported by real case studies from different EU countries.
34
Integrated Trans-IND system
Description
Innovativeness
Actors of construction
process
Page 35 of 37
Business model for value-chain integration
A new business model that is a part of the coherent operation strategy of Trans-IND to overcome the existing
market and legal barriers, especially concerning the fragmentation problem in the construction sector.
Physically, it will allow companies to create new and profitable revenue streams, and find competitive
advantage.
The new business model is geared towards the large-scale implementation of FRP in civil infrastructure
projects across the EU. Its main aspects are (1) industrialised value-chain integration (including demand and
supply chains) instead of one-off project strategy and (2) performance-based instead of lowest-price
procurement.
The new business model is built upon the knowledge of: current and future market potentials; characteristics
of the current business models; innovative asset management concept; and feasibility analysis supported by
real case studies from different EU countries.
The new business model will transform a resources-based and supply-driven construction sector into a
sustainable performance-driven sector, which is user-oriented, flexible, creative, innovative, effective and
efficient in the whole life-cycle of the civil infrastructures. Moreover, it will encourage large-scale applications
of FRP in transport infrastructures.
The new construction process and the new business model creates added values through horizontal and
vertical value-chain integration (citizens - social acceptance, end-users, regulatory and standardization
bodies, clients - public and PPP, civil engineers, construction companies, materials manufacturers,
components manufacturers/suppliers, equipment manufacturers, service suppliers, etc.) to solve the
fragmentation problems in the construction sector.
For this purpose, a full value re-engineering that integrates the demand and supply chains in civil
infrastructure projects is carried out. The focus is given on facilitating the multi-party and multi-disciplinary
collaboration processes for smart design, manufacturing and assembly of industrialised components.
Investor/Client, Main Contractor, Supplier, off-site manufacturer
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Integrated Trans-IND system
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Recommendation for standardization
Description
Recommendations for standardization of FRP (based on Trans-IND infrastructure elements, processes...)
are to be developed through collection of existing standards on FRP field, assessment, sorting, through
detailed study of literature on procedures of manufacturing, design, testing, assembly, maintenance. The
study revealed blank spots and barriers. Recommendations for standardization will gather or develop new
procedures for design, production, testing and certification. Recommendation for standardization could help
in development of Eurocode of FRPs - wider use and easier design, production, testing, education.
Scheme
Trans-IND
(1)
GENERAL
(2)
BASIC OF DESIGN
2.1.
DESIGN VALUES
2.2.
DESIGN REQUIREMENTS
2.2.1.
General
2.2.2.
Ultimate limit states
2.2.3.
Serviceability limit states
2.3.
ANALYSIS
2.3.1.
ULS
2.3.2.
SERVICEABILITY ANALYSIS
(3)
MATERIALS
3.1.
REINFORCEMENT
3.1.1.
Fibres
2.4.2.
Rovings
2.4.3.
Mats
3.1.4.
Woven rovings (WR)
3.1.5.
Fabrics
3.1.6.
Prepregs
3.2.
RESINS
3.2.1.
Polyester resins
3.2.2.
Vinyl ester resins
3.2.3.
Modified acrylic resins
3.2.4.
Phenolic resins
3.2.5.
Epoxy resins
(4)
LAMINATE DESIGN
4.1.
LAMINA DESIGN
4.2.
LAMINATE design
4.3
Test Methods
(5)
DURABILITY
5.1.
CREEP
5.2.
FATIGUE
(6)ELEMENT CALCULATION
6.1.
ULTIMATE LIMIT STATE DESIGN
6.1.1.BASIC CONDITIONS
6.1.2
Innovativeness
Actors of
process
construction
Document Recommendations for
standardisation-CONTENTS:
6.1.3
MEMBERS IN COMPRESSION
6.1.4
MEMBERS IN FLEXURE
6.1.5
MEMBERS IN SHEAR
6.1.6
COMBINATION
6.2
SERVICEABILITIY LIMIT STATE DESIGN
6.2.1
BASIS CONDITIONS
6.2.2
DEFLECTIONS
6.2.3
STRESSES AND STRAINS
(7)
JOINTS
7.1.
GENERAL
7.1.1.
Partial safety factors
7.2.
MECHANICAL JOINTS
7.2.1.
BOLTED AND RIVETED JOINTS IN SHEAR
7.2.1.1. General
7.2.1.2. Design
7.2.2.
BONDED JOINTS
7.2.2.1. General
7.2.2.2. Adhesives
7.2.2.3. Design of lap and strap joints
7.2.2.4. Design of angle joints
7.2.2.5. Design of tee joints
7.2.3.
COMBINED JOINTS
7.2.3.1. Bonded-bolted joints
7.2.3.2. Bonded-riveted joints
(10)
QUALITY CONTROL
10.1.CONTROL OF DESIGN
10.2.CONTROL OF PRODUCTION
10.3.CONTROL OF CONSTRUCTION
10.4.REGULAR INSPECTIONS
(11)
REPAIR OF DAMAGES
(12)
COMPLIANCE TESTING
12.1.1. During production
12.1.2. On site
(13)
REFERENCE LIST
10
MEMBERS IN TENSION
Figure 41: Content of the recommendations for standardisation
The end result will increase the use of FRPs. Price of construction of FRP will decrease, FRPs will be more
competitive to conventional materials. FRPs will more often be applied together with some of conventional
materials like concrete.
Designer, Structural Engineering, Main Contractor, Certification Authority, Supplier, off-site manufacture
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Integrated Trans-IND system
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Integrated Trans-IND system
The Integrated Trans-IND system is a cost-effective integrated construction process that will enable the
maximum capability of industrialization of components for transport infrastructures (deck, beam, joints,
secondary elements) using Fibre Reinforced Polymer. Trans-IND system incorporates DFMA (Design for
Manufacture and Assembly) in order to achieve reduction in the total costs by decreasing manufacturing and
assembling efforts.
Description
Scheme
Innovativeness
Actors of
process
construction
Figure 42: Main phases of the Trans-IND construction process
The Integrated Trans-IND system tends to introduce innovative solutions in every phase of the construction
process i.e. planning, design, manufacturing, on-site assembly, maintenance, renovation and demolition.
The system combines new: materials like FRP, ICT solutions like RFID system and intelligent positioning
system, approach to design, manufacturing and assembly: DFMA method and appropriate business models.
Investor/Client, Legal officer, Designer, Structural Engineering, Main Contractor, Certification Authority,
Supplier, off-site manufacture, Cost Engineer, Trainer, educator, Service Provider, Sub-contractor, Safety
Control Officer, Quality control officer
37