7/27/2019 C11-ICC ER 5558

1/3

LEGACY REPORT

Business/Regional Office# 5360 Workman Mill Road, Whittier, California 90601 # (562) 699-0543

Regional Office# 900 Montclair Road, Suite A, Birmingham, Alabama 35213 # (205) 599-9800

Regional Office#4051 West Flossmoor Road, Country Club Hills, Illinois 60478 # (708) 799-2305

ICC Evaluation Service, Inc.

www.icc-es.org

Legacy report on the 1997 Uniform Building Code

ER-5558Reissued February 1, 2004

Copyright 2004 Page 1 of 3

ICC-ES legacy reports are not to be construed as representing aesthetics or any other attributes not specifically addressed, nor are they to be construed as

an endorsement of the subject of the report or a recommendation for its use. There is no warranty by ICC Evaluation Service, Inc., express or implied, as to

any finding or other matter in this report, or as to any product covered by the report.

DIVISION: 03CONCRETESection: 03930Concrete Rehabilitation

CONCRETE AND MASONRY STRENGTHENING USING THE

HEX-3R STRUCTURAL COMPOSITE SYSTEM

HEXCEL REINFORCEMENTS CORPORATION2200 SOUTH MURRAY AVENUE

ANDERSON, SOUTH CAROLINA 29624

BONDO CORP.

3700 INDUSTRIAL PARKWAY NW

ATLANTA, GEORGIA 30331

SIKA CORP.

201 POLITO AVENUE

LYNDHURST, NEW JERSEY 07071

1.0 SUBJECT

Concrete and Masonry Strengthening Using the HEX-3RStructural Composite System.

2.0 DESCRIPTION

2.1 General:

The HEX-3R Structural Composite System is used as analternate to systems addressed in the 1997 Uniform BuildingCode (UBC), to strengthen concrete and masonry structuralelements. Table 1 summarizes all product names used byHexcel Reinforcements Corporation and the additional listees.

2.2 Materials:

2.2.1 HexWrap High-strength Fabric:The HexWrap high-strength fabric is composed of either carbon, aramid or glassfibers. HexWrap 100 is a glass-fiber, unidirectional fabricweighing 27 ounces per square yard (917 g/m2). HexWrap103 is a carbon-fiber, unidirectional fabric weighing 18 ouncesper square yard (611 g/m2). HexWrap 106 is a glassfiber,open-weave fabric weighing 8.7 ounces per square yard (295g/m2). HexWrap 107 is similar to HexWrap 100 and isadditionally composed with aramid fibers in the weft direction.HexWrap 230 is a carbon-fiber, unidirectional fabric weighing6.7 ounces per square yard (228 g/m2). Standard rolls offabric are shipped in 12-inch-by-13-inch-by-64-inch (305 mmby 330 mm by 1626 mm) boxes, and special roll sizes areavailable. Material properties vary with fiber type.

2.2.2 Hex-3R 300, 306 and 306XR Epoxy: The matrix is anambient-cure epoxy mix used to bind and environmentallyprotect the fibers. Components A and B of the matrix areshipped in either 5-gallon (18.9 L) buckets or 50-gallon (189.3

L) drums and are mixed at either the jobsite or the factory,prior to application.

2.2.3 Hex-3R Composites: Hex-3R composites arecomprised of materials covered in Sections 2.2.1 and 2.2.2 ofthis report.

2.2.3.1 Wrap 107 Composite: In the primary direction, theglass-fiber composite has a design ultimate tensile strengthof 86.6 ksi (597 MPa), design tensile modulus of 3.58 103

ksi (24.6 103 MPa), and design elongation of 2.33 percent.Layer thickness is 0.040 inch (1 mm).

2.2.3.2 Wrap 100 Composite: In the primary direction, the

glass-fiber composite has a design ultimate tensile strengthof 81 ksi (558 MPa), design tensile modulus of 3.55 103 ksi(24.4 103 MPa), and design elongation of 2.23 percent.Layer thickness is 0.040 inch (1 mm).

2.2.3.3 Wrap 103 Composite: In the primary direction, thecarbon-fiber composite has a design ultimate tensile strengthof 104 ksi (716 MPa), design tensile modulus of 9.93 103 ksi(68.4 103 MPa), and design elongation of 0.98 percent.Layer thickness is 0.040 inch (1 mm).

2.2.3.4 Wrap 230 Composite: In the primary direction, thecarbon-fiber composite has a design ultimate tensile strengthof 119 ksi (820 MPa), design tensile modulus of 10.25 10 3

ksi (70.6 103 MPa), and design elongation of 1.16 percent.Layer thickness is 0.013 inch (0.33 mm).

2.2.3.5 Wrap 106 Composite: In the primary direction, theglass-fiber composite has a design ultimate tensile strengthof 35.3 ksi (243 MPa), design tensile modulus of 2.35 msi(16.2 GPa), and design elongation of 1.43 percent. Layerthickness is 0.013 inch (0.33 mm).

2.2.4 Hex-3R FireLam 505:The Hex-3R base coat is a two-component epoxy material. Component A is packaged in 2.4-gallon (9 L) containers. Component B is packaged in 0.59-gallon (2.23 L) containers.

2.2.5 Hex-3R FireLam 506: The Hex-3R top coat is anacrylic paint packaged in 3-gallon (11.36 L) containers.

2.2.6 Storage Recommendations: For the epoxies,finishes and fibers should not be subjected to water

contamination or exposed to temperatures above 100/F

(38/C). Storage life shall not exceed one year for the Hex-3RFireLam 506, two years for the epoxies, and ten years for thefibers.

2.3 Material Properties:

All materials shall comply with specifications outlined in theHexcel Reinforcements Corporation quality control manual(hereafter referred to as the QCM), dated December 6, 1999.

7/27/2019 C11-ICC ER 5558

2/3

Page 2 of 3 ER-5558

2.3.1 Bond Strength: The bond strength of the system to aproperly prepared surface shall exceed the tensile strength ofthe substrate. Testing in accordance with ASTM D 4541 canbe used to estimate the bond strength of installations.Sufficient bond area shall be used to prevent bond failure.

2.4 Installation:

Installation shall be performed by applicators certified byHexcel Reinforcements Corporation. Installation of the systemis detailed in Section 3.2 of the Engineering Guidelines

published by Hexcel Reinforcements, dated August 1999.

2.4.1 Saturation: The fibers and the matrix are combined inaccordance with an established weight and volume ratio,using the calibrated Hex 3-R Saturator or manual methods.

2.4.2 Application: The composite fabric is applied to thesubstrate using manual methods. Manual methods are usedto remove air bubbles and to ensure desired fiber orientation.Pot life of the saturated fabric is 3 hours at 70/F (21/C), andvaries with temperature. Higher temperatures result in ashorter pot life, and lower temperatures result in a longer potlife.

2.4.3 Finishing: A final layer of thickened epoxy is appliedand can be coated with one of the following:

2.4.3.1 Paint: Paints are applied as required forenvironmental and aesthetic considerations.

2.4.3.2 Flame-spread Coating: When applied to structuralelements to satisfy code requirements for interior finish, theHex-3R FireLam 505 and Hex-3R FireLam 506 yield a ClassI flame-spread rating and a smoke-density requirement inaccordance with Section 802.2 of the UBC. The composite islimited to a maximum of six layers. Application instructions forthe Hex-3R FireLam 505 and the Hex-3R FireLam 506 arefound in Section 3.2 of the Engineering Guidelines.

2.4.4 Cure Time Prior to Loading: The Hex-3R compositesshall be allowed 48 hours of cure time prior to the loading ofthe structural member.

2.5 Design:

2.5.1 General: Design of the composite system is based onultimate strength design requirements in accordance withChapters 19 and 21 of the UBC. The owner and structuraldesign professional are responsible for determining, throughanalysis, the design strengths and demands of the structuralelements to be enhanced by the Hex-3R System.

2.5.2 Composite Design Properties: Structural designproperties for the composites are found in Section 9 of theEngineering Guidelines.

2.5.3 Design Details: Design equations are based on testresults and principles of structural analysis. Basis of designincludes strain compatibility and limit states. All designs follow

procedures as detailed in the code; in the ICC-ES InterimCriteria for Concrete and Reinforced and UnreinforcedMasonry Strengthening Using Fiber-reinforced, CompositeSystems (AC125), dated June 2003; and in the EngineeringGuidelines. The engineering guidelines also provide guidanceon protecting the composite materials in areas where they areprone to impact.

2.5.4 Factors of Safety: The strength reduction factors andload factors used shall comply with the UBC.

2.5.5 Columns:

2.5.5.1 Potential Applications: Columns can bestrengthened to enhance their ductility and their axial, flexuraland shear strengths, and to provide confinement of lapsplices of steel reinforcement.

2.5.5.2 Structural Design Requirements:Concrete designshall comply with the Engineering Guidelines and withSections 1907, 1909, 1910, 1911, 1912, and 1921 of theUBC. Masonry design shall comply with the EngineeringGuidelines and with Section 2108 of the UBC.

2.5.6 Beams and Slabs:

2.5.6.1 Potential Applications: Beams can bestrengthened to enhance their ductility and their flexural andshear strengths. Slabs can be strengthened to enhance

flexural and in-plane shear strengths.

2.5.6.2 Structural Design Requirements:Concrete designshall comply with the Engineering Guidelines and withSections 1907, 1909, 1910, 1911, 1912 and 1921 of the UBC.Masonry design shall comply with the Engineering Guidelinesand with Section 2108 of the UBC.

2.5.7 Walls and Wall-Slab Connections:

2.5.7.1 Potential Applications:Walls can be strengthenedto enhance out-of-plane flexural, in-plane flexural and shearstrengths.

2.5.7.2 Structural Design Requirements: Concrete walldesign shall comply with the DM and with Sections 1907,1909, 1910, 1911, 1912, 1914 and 1921 of the code. Masonry

wall design shall comply with the Engineering Guidelines andwith Sections 2106 and 2108 of the UBC.

2.6 Special Inspection:

Special inspection during the installation of the system shallbe in accordance with Section 1701 of the UBC. Specialinspection during installation of the system shall also be inaccordance with the ICC-ES Interim Criteria for Inspectionand Verification of Concrete and Reinforced and UnreinforcedMasonry Strengthening Using Fiber-reinforced Polymer (FRP)Composite Systems (AC178), dated June 2003.

2.7 Identification:

Products of the structural composite system are labeled, inaccordance with the QCM, with the manufacturers name andaddress, product name, expiration date, evaluation reportnumber (ER-5558) and name of the quality control agency(Underwriters Laboratories Inc.).

3.0 EVIDENCE SUBMITTED

Data in accordance with the ICC-ES Interim Criteria forConcrete and Reinforced and Unreinforced MasonryStrengthening Using Fiber-reinforced, Composite Systems(AC125), dated June 2003; and quality control manuals.

4.0 FINDINGS

That Concrete and Masonry Strengthening Using the

HEX-3R Structural Composite System described in thisreport complies with the 1997 Uniform Building Code

(UBC), subject to the following conditions:

4.1 Design and installation are in accordance with this

report, the manufacturers instructions and the UBC.

4.2 Copies of the Hexcel Reinforcements Corporation

Quality Control Manual, dated December 6, 1999,and Engineering Guidelines, dated August 1999, are

submitted to the building official for approval with

each project using the system.

4.3 Fire-resistance of the assembly must comply with

Chapter 7 of the UBC and is not reduced byapplication of the HEX-3R system. Fire-resistance of

assemblies with structural load-carrying capacitiesincreased beyond code levels by the HEX-3R system

is beyond the scope of this report. Fire protection

7/27/2019 C11-ICC ER 5558

3/3

Page 3 of 3 ER-5558

for the composite systems shall be subject tobuilding official approval.

4.4 Special inspection is provided in accordance withSection 2.6 of this report.

4.5 To satisfy Item 2, Section 215, of the UBC, regardingnoncombustible construction, the flame-spread

coating described in Section 2.4.3.2 of this report is

limited to 1/8-inch (3.2 mm) thickness, maximum.

4.6 Concrete members are fabricated by an approvedfabricator complying with Section 1701.7 of theUBC, or are fabricated with continuous special

inspections in accordance with Sections 1701.5.1and 1701.5.3 of the UBC.

4.7 Masonry members are fabricated with continuousspecial inspections in accordance with Section

1701.5.7 of the UBC.

4.8 HEX-3R materials are manufactured at 1850 South

Sequin Avenue, New Braunfels, Texas; 1913 North

King Street, Seguin, Texas; and 8250 CommercialStreet, La Mesa, California, with quality control

inspections by Underwriters Laboratories Inc. (AA-668).

This report is subject to re-examination in two years.

TABLE 1CROSS-REFERENCE OF PRODUCT NAMES

HEXCEL REINFORCEMENTS NAME BONDO NAME SIKA NAME

HexWrap Hex-3R 300HexWrap Hex-3R 306HexWrap H-3R 306XR

HexWrap Hex-3R Wrap 107

HexWrap Hex-3R Wrap 100HexWrap Hex-3R Wrap 103HexWrap Hex-3R Wrap 230HexWrap Hex-3R Wrap 106

HexWrap Hex-3R FireLam 505HexWrap Hex-3R FireLam 506

Pro Force Structural Epoxy1

Pro Force Structural Epoxy 23100

Pro Force Structural Epoxy 23500

Sikadur Hex 300Sikadur Hex 360

Sika Wrap Hex 107G

Sika Wrap Hex 100GSika Wrap Hex 103CSika Wrap Hex 230CSika Wrap Hex 106G

1Pro Force Structural Epoxy consists of HexWrap HEX-3R306 combined in a kit with HexWrap Hex-3R Wrap 100 or HexWrap Hex-3R Wrap 230.