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The purpose of this paper is twofold: first, to observe an influence of different Composite Fibre-Reinforced Polymer (CFRP) patches, whose application to metals is very easy, in suppling and significantly elongating the service time; and second, the numerical calculation of the reduced stress intensity factor (SIF) range for strengthened cracked steel specimens.

One of the successful strengthening methods is the CFRP patching along the fatigue crack paths. The presented approach has been studied and discussed in this paper on the background of the numerical and experimental data. As it was expected, the proposed strengthening method is efficient and promising in case of the “immediate” repairs of critical members with cracks. The manufacturing process of specimens and test methodology as well as numerical approach to calculate SIFs for various reinforcements of steel specimens are presented. For this purpose, the Extended Finite Element Method was involved and described.

The main mechanism of fatigue crack growth retardation is associated with local ΔK reduction due to CFRP patches; any type of reinforcement results in an increase in a_f and a significant decrease in SIF values. The beach-marking method is described as a good, reliable and comprehensive method to capture the crack propagation in structures consisting of various materials and could be applied successfully for mixed mode testing.

A detailed experimental-numerical approach for fatigue crack growth in long-term operated structures made of steel is presented. The strengthening methodology is presented with consideration of the various CFRP patches configurations.