Seminar m3 S

Performance of SIFCON as a Strengthening Material
CHAPTER 1
INTRODUCTION
1.1 GENERAL
The construction of long span bridge, high rise building, offshore structures, and other mega
structures requires materials, with increasingly improved properties such as particular
strength, stiffness, toughness, ductility and durability. In most instances, simultaneous
improvement in a combination of these properties is needed. Such material often called
“High Performance Materials” and “Advanced Materials”. They are basically different from
other conventional materials.
Recently many types of High Performance Fiber Reinforced Cement (HPFRC) composites
have been developed. These materials have high strength, ductility and toughness which
make them ideal materials for structural repair and retrofit. Among several types of HPFRC
composites, Slurry Infiltrated Fiber Concrete (SIFCON) is a type of concrete in which
formwork moulds are filled to capacity with fibers and then the resulting fiber network is
infiltrated by cement-based slurry. Infiltration is usually accomplished by gravity flow aided
by a light vibration or pressure grouting. The volume fraction of fibers in SIFCON is 4–25%
compared to 0.5–3% in conventional fiber reinforced concrete. Infiltrated grout in SIFCON
with very fine aggregate makes it a ductile and a high performance material. Elastic modulus
and maximum strain capacity as much as 13,800 MPa and 1.5%were reported for SIFCON
materials with 10% of steel fibers. Also, ultimate strain capacity of SIFCON can reach and
even exceed the yield strain of mild steel rebars. SIFCON has been used successfully for
refractory applications, pavement overlays, and structures subjected to blast and dynamic
loading. Because of its highly ductile behavior and far superior impact resistance, the
composite has excellent potential for structural applications in which accidental or abnormal
loads such as blasts are encountered during service. SIFCON also exhibit new behavioral
phenomenon, that of “Fiber lock” which believed to be responsible for its outstanding stress-
strain properties. The matrix in SIFCON has no coarse aggregates, but a high cementitious
content. However, it may contain fine (or) coarse sand and additives such as fly ash, micro
silica and latex emulsions.
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The unit weight of SIFCON is typically higher than concrete and normal FRC because of the
relatively heavy weight due to its high fiber content. For a slurry unit weight of 1920 kg/m3
the addition of steel fibers results in an increase in density varying from 2160 to 3130 kg/m3
for steel volume fraction ranging from 5 to 20 volume percent. The unit weight increase is
almost linearly proportional to the fiber content.
SIFCON composites subjected to compression and tension and found that shows better
behaviour of stress-strain curves. The addition of different types of mineral admixtures
influences the overall behaviour of this material and results showed that by the addition of
high volume fiber content (2%) and blast furnace slag into the mix performs well compared
to silica fume and lesser volume of fiber content. There is an improvement in toughness due
to incorporation of steel fibres in the matrix. Incorporation of silica fume, addition of fiber
content and aspect ratio increases the toughness value. SIFCON specimen exhibit better
ductility characteristics and higher resistance to cracking and spalling effects. SIFCON is
one of the innovative building material comprising higher strength and larger ductility. It
consists of discrete interlocking fibres which attribute to its enhanced tensile properties,
similar to Fiber Reinforced Concrete (FRC). Fiber alignment affects the behavior of a
SIFCON product greatly. Fibers can be aligned parallel to the stress direction which will be
taken place within the composite or can be placed randomly. The ultimate strength, residual
strength, ductility, and energy absorption properties are all can be affected by the fiber
alignment. SIFCON has superior mechanical properties such as compressive, tensile, shear
and especially flexural strengths with extraordinary toughness values. The mechanical
properties of SIFCON depend on fiber and slurry properties such as fiber type, volume,
alignment, compressive strength and modulus of elasticity of slurry. Superior toughness
property of SIFCON demonstrates the potential usage area in industrial floors, strengthening
and retrofitting works, explosion resistant military structures, and seismic resistant structures.
SIFCON which will be used in strengthening works as well as military structures may be
exposed to high temperatures for reasons such as fire and explosion. One of the most
significant physical deterioration processes that influences the service life of cement based
composites is high temperature exposure.
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1.1 SIFCON DESIGN PRINCIPLES
A high strength SIFCON mix can easily be designed and obtained with virtually any type of
steel fibers available today, if slurry is also of high strength like conventional concrete.The
strength of slurry is a function of water-cement ratio, because the slurry mixes used in
SIFCON usually contain significant percentages of fly ash or silica fume or both. The term
“water-cement plus admixtures” is used when designing slurry mix. In addition, the ratio of
“admixtures to cement” is also an important parameter in design of SIFCON, higher volume
percentages of fibers need lower viscosity slurry to infiltrate the fibers thoroughly. Generally,
higher the slurry strength greater is SIFCON strength.
1.2 Factors affecting SIFCON efficiency
The following factors affect the strength of SIFCON.

i. Slurry strength
ii. Fiber volume
iii. Fiber alignment
iv. Fiber type
The ultimate strength, ductility and energy absorption are all affected by fiber alignment.
1.3 Advantages of SIFCON
i. SIFCON possesses excellent durability, energy absorption capacity, impact and abrasion
resistance and toughness.
ii. Modulus of elasticity (E) values for SIFCON specimens is more compared with plain
concrete.
iii. SIFCON exhibits high ductility.
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1.4 PREPARATION OF SIFCON
The process of making SIFCON is different, because of high steel fiber content. While in
SFRC (Steel Fiber Reinforced Concrete), or dry mix of concrete, prior to mix being poured
into forms.(Reframe this in to meaningful sentence) SIFCON is made by infiltrating low
viscosity cement slurry in to a bed of steel fibers “pre packed” in forms or moulds.
Step1: Steel fibers are preplaced in the mould.
Step2: Cement, sand, fly ash is weighted and mixed with water, super plasticizer for making
slurry.
Step3: Concrete is poured into the mould.
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CHAPTER 2
LITERATURE REVIEW
2.1 GENERAL
Many researches are being conducted on SIFCON due to its strengthening properties.. A
brief review on literatures of SIFCON as construction material is discussed below.
2.2 LITERATURES ON SIFCON
Elevarashi et al.(2018) explored the response of thin slabs of Slurry-Infiltrated Fibrous

Concrete (SIFCON) with and without reinforcement under low velocity impacts is explored
via drop-hammer impact experiments. For comparison purpose, plain cement concrete (PCC)
and reinforced cement concrete (RCC) slabs were also cast and tested. SIFCON slabs are
made with binary cementitious materials. The pre-determined concrete mixtures were
designed with 15% of silica fume, 30% of blast furnace as a partial substitute of cement
along with a constant 10% of hooked end steel fibres by volume fraction. The replication of
a low-velocity impact on slab was achieved by dropping a steel ball (weighing 4.5 kg), with
fall height of 457 mm, via the utilization of a self-fabricated drop-hammer impact test device.
The parameters like first crack and ultimate failure energy absorption capacity, ultimate
crack resistance, crack resistance ratio, ductility indices, and failure pattern were examined.
The test results reported that the incorporation of binary blends of silica fume and slag in
SIFCON matrix shows better performance in terms of strength and durability characteristics.
_
Jung et al. (2017) investigated the behaviour of high performance fiber reinforced
cementitious composites. As the threat of global terrorism increases a demand for
reinforced concrete structures as a physical protection also become more important. The
protective structures are to withstand sudden occurrence of dynamic loads like terrorist
impact and blast attacks as well as vehicle and industrial accidents. In order to resist such an
expected loading, the HPFRCC (High Performance Fiber Reinforced Cementitious
Composite) materials may take an appropriate role by its increased fracture energy
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absorbing capacity. The slab member was 100mm thick and 2000mm squared SIFCON
(Slurry Infiltrated Concrete) based HPFRCC and the outer surface was wrapped with basalt
fiber sheet. By wrapping the basalt, the specimen may attain more confining effect and the
final HPFRCC is named as KNU HPFRCC. The SIFCON has about 80MPa compressive
strength with steel fiber volume fraction of 5%. The used steel fibers were 60mm long with
aspect ratio (80) and its tensile strength was 1100MPa. The slurry composed of ordinary
Portland cement, water, fine sand and silica fume.
Beglarigale et al. (2016) proposed high temperature resistance of SIFCON. High

temperature resistance is one of the most important parameters which affects the durability
and service life of materials. Due to synergistic interaction of different mechanisms,
mechanical performance can be lowered especially for the multi-component composite
materials exposed to high temperature. Standard or steam cured slurry infiltrated fiber
concrete (SIFCON) and slurry specimens were subjected to 300, 600, 750 and 900 0C.
Exposing the specimens to 300 ⁰C enhanced the mechanical performance, while higher
temperatures have detrimental effects on the SIFCON composites such as the loss in the
cross section of steel fibers and the destruction of C–S–H structure and discussed
temperature resistance of SIFCON composites.
Abdollahi et al. (2012) presents SIFCON strengthening as a new method of confinement in

comparison with GFRP confinement. The experimental part of the work is focused on the
investigation of confinement in concrete specimens with unconfined strength ranging from
15 to 40 MPa, enclosed with GFRP sheets or SIFCON jacket. Several parameters such as
number of layers and ply configuration for GFRP method and jacket strength, fiber length
and jacket thickness for SIFCON method have been investigated. Furthermore, the ultimate
strength models of FRP-confined concrete have been classified and evaluated with test
results and the first step in modeling the ultimate strength of SIFCON-confined concrete has
been taken. The results show that SIFCON confinement method can be regarded as a
competitive method with respect to the well-known FRP confinement method and some of
the available models of FRP confinement can also give good estimation of the ultimate
strength of concrete confined by SIFCON method.
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CHAPTER 3
MECHANICAL PROPERTIES OF SIFCON
3.1 GENERAL
This chapter deals with the results of an experimental study in which steel fibers recovered
from scrap tyres were used to produce slurry infiltrated fiber concrete (SIFCON). The fibers
were preplaced into molds, and then infiltrated by flowable cement slurry which has a low
water/cement ratio. Mixtures with different fiber contents were cast. A plain mixture without
fibers was also prepared for reference. Compressive strength, splitting tensile strength and
flexural strength of the mixtures were determined.
3.2 MATERIALS USED
3.2.1 Cement and aggregate

An ordinary Portland cement (CEM I 42.5) was used in all the mixtures. The aggregate used
was a siliceous sand with a maximum particle size of 0.5 mm. Percentages passing from
0.25 mm and 0.125 mm sized sieves were 53% and 6%, respectively. The aggregate grading
and the maximum particle size of the aggregate were kept constant in all the mixtures. The
specific gravity of the sand was 2.63. A plasticizer admixture was also added in order to
reduce the water requirement and to maintain the workability.
3.2.2 Fibers
Waste steel fibers from different tyre recycling plants as shown in Fig.1 were considered for
preliminary study. The fibers recovered by mechanical processing were containing varying
amounts of textiles and rubber which may be due to the recycling methods of the plants. The
received fibers were compared based on their fiber and rubber content. The geometrical
properties were also considered. Some of the fibers received were containing textiles and
rubber and their total amount varied between 17 and 32% by weight. Removing these
materials from the steel fibers was a time consuming and labor intensive process, thus such
fibers were not considered in the experimental study. Tensile strengths were higher than
1000 MPa, and can be classified as high strength steel.
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Fig 1: Waste steel fibers used in the study [1]
Table 1: Mix Proportion of different mixes [1]
Cement(Kg/m3) 960
Water –Cement ratio 0.33
Cement sand ratio 1
Superplasticizer 1.5% of cement weight
Trials shown that the maximum amount of waste steel fibers that can be used without the
fibers bulking up was slightly higher than 5% and as a result, fiber content of 5% by volume
was selected as the upper limit of fiber content in the study. Fiber content of the mixtures
was increased with the steps of 1%. A mixture was also prepared with 0.5% of fibers. In
addition, a reference mixture that does not contain any fiber was also produced. As a result,
mixtures containing 0, 0.5, 1, 2, 3, 4 and 5% of waste steel fibers by volume were prepared.
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3.3 CASTING OF SPECIMENS
Since the waste steel fibers used in this study had much longer lengths compared to
conventional fiber lengths, only prism specimens of 70 × 70 ×280 mm were cast. As a first
step of the testing program, bending test was performed on the prisms. After this testing, the
broken prisms were cut using a diamond saw and cube specimens having dimensions of 70 ×
70 × 70 mm were obtained. The cubes were cut out from each end of the prisms where
bending stress is not effective and there were no cracks or any other effects of the bending.
As mentioned above, seven mixtures were prepared. Five prism specimens were cast for
each mixture. Thus, for each mixture, five of these cubes were tested for compressive
strength and the other five cubes for splitting test. In both of these tests, the molded surfaces
of the cubes were used as the load bearing surfaces. All the tests were performed at the age
of 28 days.
3.4 TESTING OF SPECIMEN

3.4.1 Compression test
The tests were carried out at a uniform stress after the specimen has been centered in the
testing machine. Loading was continued till the dial gauge needle just reverses its direction
of motion. The reversal in the directions of motion of the needle indicates that the specimen
has failed. The dial reading at the instant was noted, which is the ultimate load. The ultimate
load divided by the cross section area of the specimen is equal to the ultimate cube
compressive strength.
Compressive strength = load / area (N/mm2)
3.4.2 Split tensile strength

The test was carried out by placing a cylindrical specimen horizontally between the loading
surfaces of a compression testing machine and load is applied until failure of cylinder, along
the vertical diameter
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3.4.3 Flexure strength

Net flexural strengths were obtained according to equation
3Pl
f=
2 B( D  a0 ) 2
where f is the net flexural strength (MPa), P shows the maximum load (N), l represents the
span (mm), a 0 indicates notch depth (mm), B is the width and D is the height (mm).
3.5 RESULTS AND DISCUSSIONS

3.5.1 Compressive Strength
Fig 2: Effect of waste steel fiber content on the compressive strength of SIFCON [1]
Average compressive strength is shown in Fig 2. Compressive strength of the cement slurry
without fibers was 94.7 MPa which indicates that the matrix phase (slurry) of SIFCON
mixtures is a high strength material. Although some of the mixtures have lower strength,
these reductions were only between 1% and 8% when compared to plain mixture. Among
the mixtures prepared, the lowest compressive strength was obtained on the one containing
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2% of fiber which was 87.3 MPa. On the other hand, the compressive strength of the
mixtures containing 1% and 4% fiber had higher strengths than the reference mixture. The
highest strength was obtained in the mixtures produced with 4% of fiber but it was only 2%
higher than that of the reference mixture without any fibers.
The values are close to each other and no specific trend was observed between the
compressive strength and fiber content. There may be several reasons behind such a result.
A possible reason behind these changes in the compressive strength may the natural scatter
of test results. Another possible reason may be the wall effect at the end portion of the
prisms. The wall effect may occur at the edges of the samples due to loose packing of the
long fibers. The cubes used in compression test were cut out from the end portion of the
prisms. As seen in, standard deviations are higher when the amounts of fibers are increased.
These higher standard deviations may be an indication of insufficient placement of the slurry.
The slurry might not fully penetrate between the replaced fibers, thus the deviations may
increase and reduce the results obtained. In smaller fiber contents, due to the loose packing
of fibers caused by the wall effect, thus better placement of the slurry, the strength
reductions may be low.
3.5.2 Split Tensile Strength
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F
ig 3: Splitting tensile strength of the SIFCON mixtures [1]
Fig. 3 shows the change in the average splitting strength of SIFCON mixtures. These
strengths increased substantially as higher amounts of fibers were used. For example, the
result obtained for 0.5% of fiber was 12.6 MPa but this strength was 25.4 MPa for the fiber
content of 5%, which corresponds to a strength increase of more than 2 fold. As seen in
the above figure, there is a strong relationship between the fiber content and splitting tensile
strength and the high correlation coefficient (R = 0.99) confirms the good correlation
between these two parameters. In splitting tensile test set-up, compressive load is applied
along two opposite lines, which creates tensile stresses that are perpendicular to the loading
path.
These tensile stresses normal to the plane of load result in splitting failure of the concrete. If
there are fibers along this path, they restrict the crack propagation, thus, splitting strength
obtained is affected. The number of fibers bridging the fracture plane increases with the
fiber content which increase the splitting strength. During the loading, rupture of the fibers
may occur or they may be pulled out from the matrix phase. The waste fibers were
substantially longer compared to conventional steel fibers, which may also have a
contributing effect on the bonding of the fiber and affects the obtained results..
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3.5.3 Flexure strength
Average flexural strengths of the SIFCON mixtures are shown in Fig. 4. As seen in the test
results, the flexural strength of the mixtures increased substantially with increasing amounts
of waste steel fibers. The result obtained for the one with 5% of waste fiber was 63.8 MPa.
This result can be attributed mainly to the length of the waste steel fibers used. The bonding
between the fibers and matrix was high due to the lengths of the fibers used. It should be
noted that the strength of the slurry was also high because of the low water/cement ratio.
Although the fibers were placed randomly into the moulds, due to the lengths of the fibers,
there was some orientation of the long fibers parallel to the long axis of the prism mold. This
partial alignment might have additional contribution to the flexural strengths of the mixtures.
Fig 4: Effect of waste steel fiber content on the flexural strength of SIFCON[1]
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3.5.4 Load-deflection curves
Fig. 5 compares the complete load – deflection curves of the mixtures with various fiber
contents and the one recorded for the plain mixture has also been included in the same figure.
For each fiber amount, a typical test result was used in the figure. The maximum load of the
plain mixture without fibers was approximately 2500 N and after this value, the load
decreases substantially, which represents the brittle type of behavior in mixtures without
fibers. Compared to fiber reinforced mixtures, the peak load obtained in the plain mixture
was much lower and as a result of this load value and steep descending behavior, the load
deflection curve of the plain mixture is barely visible in Fig. 4. Test results indicated that the
maximum loads carried by the specimens increased with the fiber content. After the peak
loads, the descending branches obtained for the fiber reinforced mixtures were less steep.
Since the descending branch of the load – deflection curve indicates the brittleness of the
material; these results indicate that the mixtures become ductile with the use of fibers, which
is a well known advantage of fiber reinforced mixtures. Thus, it is seen that the contribution
of waste fibers to the ductility of the mixtures was similar to that of conventional fibers. The
bending test was continued up to a deflection of 5 mm. This value was chosen because, as
seen in Fig. 4, the trend of the descending part of the curves did not change significantly
after a deflection of approximately 3 mm. As presented in this figure; except for the plain
mixture without any fibers. The flexural loads carried by the specimens were still not zero
even for the deflection value of 5 mm.
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Fig 5: Load-deflection curve of SIFCON specimens [1]
3.6 SUMMARY
Compressive strength was not affected by the use of waste steel fibers. However, both
splitting and flexural strengths of the mixtures increased with higher amounts of waste fibers.
The increases in flexural strength were more significant. A possible reason behind these
increases may be length of the fibers.
CHAPTER 4
PERFORMANCE OF SIFCON SLABS UNDER IMPACT LOADING
4.1 GENERAL
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The studies on performance of SIFCON slabs under impact loading are still lacking and
therefore a greater understanding of this topic is very much needed. This study examined the
impact response of thin SIFCON slabs with and without reinforcement, likewise PCC and
RCC slabs were also fabricated and tested for comparison purpose. Investigations were
carried out to determine the impact strength and crack resistance of slurry infiltrated fibrous
concrete made with binary cementitious materials such as silica fume and blast furnace slag.
Compressive strength, split tensile strength were found for obtaining optimum percentage of
silica fume and blast furnace slag. For strength and durability studies SIFCON made with
different percentage of silica fume (5, 10, 15, 20 & 25%) and slag (15, 30, 45, 60 & 75%)
replaced by cement was used.
4.2 MATERIALS USED
4.2.1 Cement
Ordinary Portland cement grade of 53 and specific gravity of 3.1 was used as per IS codal
provision conforming to IS: 12269.
4.2.2. Mineral admixtures
To enhance the properties of slurry mix and improving strength and durability
characteristics the supplementary cementitious materials such as silica fume conforming to
ASTM C 1240 and slag conforming to ASTM C 989 were used. The specific gravity of
silica fume and blast furnace slag are 2.63 and 2.85 respectively.
4.2.3. Fine aggregate
The maximum size of sand particle as 4.75 mm which is passing through 4.75 mm set of
sieve available from local source. The fineness modulus and specific gravity of fine
aggregate were found to be 2.41% and 2.71 respectively.
4.2.4. Fiber
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Hooked end steel fiber having a circular cross section of 1 mm diameter, aspect ratio of 30
and tensile strength of 1056 MPa was used. The hooked end fibres gives better bond
between the matrixes thus provide good resistance to impact and abrasion. The fibres were
oriented in random manner.
4.2.5. Steel reinforcement
Two way slabs were reinforced with HYSD deformed bars of 8 mm diameter at a constant
spacing of 150 mm c/c provided.
4.2.6. Water
Clean and fresh water was used for casting and curing of the SIFCON specimens
conforming to IS 456-2000.
4.2.7. Superplasticizer
To improve the flow ability of slurry infiltrated into the closely packed bed of fiber a high
range water reducing admixture CONPLAST 430 was added.
4.2.8. Mix proportions

Specific gravity of silica fume and blast furnace were found to be 2.63 and 2.85 respectively.
The slurry consists of a constant mix ratio of 1:1 and water / binder of 0.4 were used. The
mineral admixtures such as silica fume and slag were partially replaced by cement in the
matrix. The proportions slurry of different mixes was given in Table 1.
Table-2: Mix proportions of different mixes[2]
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Type Mineral % Cement Silica Slag Sand Water SP Fibre

of admixture replacement (kg/m3) fume(kg/m3) (kg/m3) (kg/m3) (Lit./m3) (Lit./m 3) content
mix (kg/m3)
SIF 950.0 950 380 19 785

SIF Silica 5 902.5 47.5 950 380 19 785
fume(SF)
SIF SF 10 855.0 95.0 950 380 19 785
SIF SF 15 807.5 142.5 950 380 19 785
SIF SF 20 760.0 190.0 950 380 19 785
SIF SF 25 712.5 237.5 950 380 19 785
SIF Slag(S) 15 807.5 142.5 950 380 19 785
SIF S 30 665.0 285.0 950 380 19 785
SIF S 45 522.5 427.5 950 380 19 785
SIF S 60 380.0 570.0 950 380 19 785
SIF S 75 237.5 712.5 950 380 19 785
4.3. CASTING OF SPECIMENS
Table 2 shows the mix proportions of different mixes. Cubes of size 100×100×100 mm for
compressive strength, 100 mm diameter and 200 mm height for split tensile strength. The
slurry was prepared based on mix proportions of rich mortar mix 1:1 and a constant W/B of
0.4 was used which is infiltrated into the prepacked fiber bed. Hand compaction was done to
ensure slurry was infiltrated into the full depth of mould.
4.3.1 Casting of slabs without reinforcement
The moulds were placed on a smooth leveled surface and oil coating was done on the sides
of the mould for removal of the specimen from the mould. Initially the fibres were filled in
the mould and cement based slurry was prepared in a constant ratio of 1:1 with water/binder
of 0.4. For improving the workability and flow ability of the matrix into the pre packed fiber
bed 2% of super plasticizer was added during mixing of slurry. Hand compaction was done
to ensure the slurry was fully penetrated into the full depth of the fiber bed. The specimens
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were demoulded after 24 h and then cured water for 28 days. After curing the specimens
were taken away from water and allowed to dry for one day at room temperature. For getting
clear visibility of formation of first and ultimate failure, white washing was done on top and
bottom surface of the slab.
4.3.2. Casting of slabs with reinforcement
The SIFCON slab specimens were reinforced with HYSD bar of Fe415 having a diameter of
8 mm at a spacing of 150 mm c/c on both ways. The rebars were kept over a preplaced fiber
bed of 10 mm thick and the remaining fibers were distributed randomly into the mould.
Then the slurry was poured into the full depth of prepacked fiber bed. Hand compaction was
done during casting of the specimen. After 24 h the specimen was demoulded and cured for
water at 28 days and allowed to dry for white washing.
4.4.1 Compression test
The tests were carried out at a uniform stress after the specimen has been centered in the
testing machine. Loading was continued till the dial gauge needle just reverses its direction
of motion. The reversal in the directions of motion of the needle indicates that the specimen
has failed. The dial reading at the instant was noted, which is the ultimate load. The ultimate
load divided by the cross section area of the specimen is equal to the ultimate cube
compressive strength.
Compressive strength = load / area (N/mm2)

4.4.2 Split tensile strength
The test is carried out by placing a cylindrical specimen horizontally between the loading
surfaces of a compression testing machine and load is applied until failure of cylinder, along
the vertical diameter.
4.4.3 Impact test
The drop weight impact testing setup has been fabricated as per ACI Committee 544.2R-89
for testing of slab subjected to impact loading. The schematic diagram of the drop weight
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impact testing setup is shown in Fig 5. The impact testing machine consists of a steel ball of
4.5 kg which is connected to a steel wire and passing over a pulley for up and down
movement. Slabs were kept simply supported over a welded channel section below the drop
weight test set up. The impact test was carried out by dropping a steel ball. It hits the slab
exactly on its centre at a height of 457mm. The number of blows required to cause the
initiation of first crack (N1) and ultimate failure (N2) were observed through visual
observation. The energy absorption capacity at the initiation of first crack (E1) and ultimate
failure (E2) of the slab specimens were determined from the following expressions.
Energy absorption capacity= mgh × N
where
m = mass of ball (4.5 kg)
g = acceleration due to gravity (9.81 m/s2)
h = height of falling (457 mm) and N is the number of blows
Fig 6: Drop weight impact test up[2]
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Table 3: Optimisation of silica fume and blast furnace slag in SIFCON [2]
Type of mix Mineral % Compressive Split tensile

admixtures replacement strength(N/mm2) strength(N/mm2)
SIF 65.50 11.03
SIF SF 5 65.80 12.52
SIF SF 10 66.17 13.33
SIF SF 15 66.50 13.40
SIF SF 20 64.91 12.83
SIF SF 25 58.69 11.14
SIF S 15 67.25 14.67
SIF S 30 74.12 15.08
SIF S 45 68.75 14.78
SIF S 60 66.04 12.06
SIF S 75 59.73 11.98
The highest compressive strength was attained at 15% of silica fume and 30% of slag as
66.5 N/mm2 and 74.12 N/mm2 respectively. Slag based SIFCON matrix shows better
performance when compared to SIFCON containing silica fume. The strength characteristics
of SIFCON with and without mineral admixtures performed well compared to plain cement
concrete. The splitting tensile strength of different mixes was presented in Table 2. From the
test results it was found that the optimum percentage of silica fume and slag are 15% and
30% respectively. When comparing to silica fume based matrix, slag shows better split
tensile strength.
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Table 4: Impact strength of SIFCON with mineral admixtures with and without
reinforcement [2]
Sl.No Type of Compressive Split No of blows required Blows

mix strength(N/mm2) tensile difference
strength at first Ultimate (N2-N1)
(N/mm2) crack(N1) failure(N2)
1 PCC(CS) 52.87 5.86 10
2 RCC(CS) 52.87 5.86 10 117 107
3 SIF(0) 65.50 11.03 246 1005 759
4 RSIF(0) 65.50 11.03 715 2364 1649
5 SIF(SF) 66.50 13.40 273 1032 759
6 RSIF(SF) 66.50 13.40 742 2572 1830
7 SIF(S) 74.12 15.08 303 1112 809
8 RSIF(S) 74.12 15.08 836 2740 1904
PCC (CS) – Control specimen, SIF10(0) – SIFCON without mineral admixtures, SIF – Unreinforced
specimen, RSIF – Reinforced specimen
4.5.1 Failure pattern

The failure pattern of different slab specimens subjected to impact loading was shown in Fig.
Punching shear failure was occurred at the top surface and shear cracks were at the bottom
surface of the slab in reinforced slabs. The level of damage was increased with increasing
the number of blows and observed that it was found to be lesser in reinforced SIFCON slabs
compared to unreinforced slabs. Among the reinforced slab specimens the damage level was
quit less with more of blows and also the formation of cracks were propagating into the
outer edge of the slab in SIFCON without mineral admixtures. Both silica fume and slag
based SIFCON, the damage occurred more at centre and the cracks formation is not
extended to the periphery of the slabs. SIFCON without conventional reinforcement slab
shows lesser level of crushing failure occurred and mortar is converted into powder form as
shown in Fig 6a when compared to other slab specimens. Comparing with SIFCON slabs the
damage level was more in RCC specimen with lesser amount of energy absorption at the
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ultimate failure as shown in Fig 6b. The mode of failures was observed in PCC and RCC
slabs as shown in Fig. 6a and Fig. 6b respectively. It is clearly observed that the PCC slab
was broken into four pieces after 10 blows because of brittle in nature and punching shear
failure was occurred in RCC slab at its centre and extended into the full depth of slab after
117 blows.
Fig 7a: PCC slab after 10 blows[2] Fig 7b:RCC slab after 117 blows[2]
Fig 8a:RSIF(0)specimen after 2364 blows[2] Fig 8b:SIF(0) specimen after 1005 blows[2]
23
Fig 8a:SIF(SF) specimen after 1032 blows[2] Fig 8b:RSIF(SF) specimen after57blows[2]
Fig 9a:SIF(S) specimen after 1112 blows[2] Fig 9b:RSIF(S) specimen after2740blows[2]
4.6 SUMMARY
Binary cementitious blends of silica fume and ground granulated blast furnace slag can be
utilized effectively as an alternative source for cement, reducing the consumption of
24
cement,saving energy and environment. When comparing to the silica fume, slag based
matrix shows better performance of strength and durability characteristics.
CHAPTER 5
FLEXURAL PERFORMANCE OF SIFCON
5.1 GENERAL
High temperature resistance is one of the most important parameters which affects the
durability and service life of materials. Standard or steam cured slurry infiltrated fiber
concrete (SIFCON) and slurry specimens were subjected to 300, 600, 750 and 900ºC.This
study aims to clarify high temperature resistance of SIFCON composites.
5.2 MATERIALS USED
5.2.1Cement
Ordinary Portland cement grade of 53 and specific gravity of 3.15 was used as per IS codal
provision conforming to IS: 12269.
5.2.2Mineral admixtures
To enhance the properties of slurry mix and improving strength and durability
characteristics the supplementary cementitious materials such as silica fume and granulated
25
blast furnace slag were used. The specific gravity of silica fume and granulated blast furnace
slag are 2.2 and 2.9 respectively.
5.2.3Fine aggregate
The maximum size of sand particle as 4.75 mm which is passing through 4.75 mm set of
sieve available from local source. The fineness modulus and specific gravity of fine
aggregate were found to be 2.41% and 2.60 respectively.
5.2.4 Fiber
Steel fiber with the characteristics of 0.55 mm diameter, 30 mm length, 1100 MPa tensile
strength, 210 GPa modulus of elasticity, and 55 aspect ratio was used at a dosage of 20% by
volume. Fiber volume was calculated according to the volume of the mold for each
specimen.
5.2.5 Water
Clean and fresh water was used for casting and curing of the SIFCON specimens
conforming to IS 456-2000.
5.2.6 Superplasticizer
To improve the flow ability of slurry infiltrated into the closely packed bed of fiber a high
range water reducing admixture of a polycarboxylate type superplasticizer is used.
Mix proportions
Mix proportions of different mixes is shown in table 5
Table 5: Mix proportion of SIFCON matrix [5]
Components Quantity
Cement(kg/m3) 400
GGBS(kg/m3) 400
SF(kg/m3) 80
Water(kg/m3) 265
26
Sand(kg/m3) 990
Superplasticizer(l/m3) 44
Water/cement 0.66
Water/binding 0.30
Standard curing(Mpa) 76
Steam curing(Mpa) 80
5.3. CASTING OF SPECIMEN
Prismatic specimens (25 × 60 × 305 mm) were used to determine the flexural strength and
toughness of the SIFCON composites. At the first stage, fibers were pre-placed into the
molds and then slurry was poured. Fibers were aligned parallel to the longitudinal dimension
of the molds by hand. Fiber orientation enhances mechanical performance, particularly
flexural properties of SIFCON. The fiber alignment can be applied in prefabricated elements,
while it is not practical in situ applications like industrial floors. In this study, the steel fiber
volume fraction was 20%. The existing spaces between the fibers (the 80% of the mold
volume) were filled completely by the slurry.
Specimens were kept in saturated humid air at 20 ± 2 ºC for 24 h and then, the specimens
were demoulded. The specimens were cured in water for 28 days. The temperature of water
curing was fixed in 20 ± 2ºC. Six hours after casting, other group of specimens was put in
steam curing cabinet. After 6 h, the temperature of the cabin was reached to 100 ºC and the
specimens were kept in this condition for 12 h.
Before subjecting the specimens to the high temperature, half of the specimens were kept in
water (saturated-surface-dry) to investigate the effect of moisture content on temperature
resistance of the SIFCON specimens. Other specimens were dried at 50ºC for 48 h. The
specimens were subjected to 300, 600, 750, and 900ºC in the oven for 3 h. Three specimens
were tested for each exposure condition. The average heating rate of the oven was 2.5
ºC/min, afterwards, the oven was opened and the specimens were cooled slowly.
27
The flexural strength and the load–deflection graphs were determined by carrying out three-
point bending tests by an electro mechanic closed-loop testing system. In order to achieve a
stable fracture test on the brittle matrix and to obtain the post peak softening branch of the
hardened slurry, a lower loading rate was applied for plain mortars similar to the previous
study. However, in this study the thin plate specimens with only 25 mm height did not
allowed to obtain the softening branch under flexural loads. Thus, bending test was applied
to the plain mortars and SIFCON specimens at 0.05 mm/min and 0.5 mm/min loading rates,
respectively. The ultimate displacement level is about 0.2 mm for plain mortar without
fibers, while this value reached 15 mm for the fiber incorporated specimens. This means that
if the 0.05 mm/min loading rate was applied to fiber reinforced mortars, only the test period
of one of the specimens will be approximately about 300 min along which is not practical. In
addition, loading ratedifference between plain and SIFCON specimens has negligible effects
on test results according to preliminary tests. Mid-span deflection was measured with an
optical encoder. The specimens were loaded from their mid span and the net distance
between simple supports was 270 mm. The toughness values were calculated using the area
under load–displacement curves. The samples for micro structural investigations were
prepared by taking small pieces from the specimens.
Fig 10:Load displacement curve of ( a)standard water cured (b)steam cured plain mortar
specimens[5]
28
Fig 11: Plain mortar specimen subjected to high temperature [5]
The load–deflection curves of binder slurry (plain mortar) are presented in Fig. 10. The
specimens which were subjected to the flexural strength test were in thin plate form and did
not contain any course aggregate. Due to these conditions, the crack-bridging phenomenon
by aggregate or fiber did not occur and a brittle fracture was observed under bending loading.
The slurry specimens could not withstand high temperature. The specimens were exploded
in the oven at a temperature level of 240–280 ºC (Fig. 11). The explosion can be explained
by the narrow and discontinuous pore structure of matrix due to the absence of course
aggregates, low water/binder ratio, and incorporation of silica fume. As can be seen from
Fig 10, the maximum flexural loads of the steam cured plain mortar are 1.8 and 3 times of
the water cured ones in saturated-surface-dry (SSD) and dried (Oven)
conditions,respectively.The specimens were fractured in a brittle manner. In other words, a
sudden load drop was occurred after the maximum load in plain mortar specimens. The
displacement at peak load and peak load value decreased remarkably by oven drying process
(50–70%). This behavior is more obvious in water cured specimens than steam cured ones.
The crack pattern of oven dried specimens was rough; while the crack in SSD specimens
was occurred in a straight path. This can be explained by micro crack formations during
29
drying.
Fig 12: Load–displacement curves of the SIFCON specimens after high temperature exposure[5]
The load–deflection curves of the SIFCON composites are presented in Fig. 12. The fibers
changed the fracture behavior of composites completely. Even for 10 mm deflection,
SIFCON composites were still carrying approximately 40% of the maximum load. As
mentioned later, all of the plain specimens without fibers subjected to the high temperature
were exploded however; inclusion of fibers prevented the explosion of SIFCON composites.
The saturated-surface-dry and oven-dried conditions did not affect the strength of the
SIFCON specimens significantly. A noticeable increase in peak load was observed at
300⁰ C. The strength may be attained by the relief of pressures through drying, which also
creates greater van der Waals forces with a closer configuration of capillary pores. Second
mechanism can be related to the hydration of unhydrated cement particles. The attained
strength may also be explained by the formation of tobermorite which was formed by the
pozzolanic reaction between the unhydrated blast furnace slag particles and lime Finally, the
drying shrinkage of the C–S–H structure may compact the fiber–matrix interface.As can be
seen from Fig. 7 the peak load of all specimens was decreased approximately by 40% at
600 ⁰C. However, the flexural strength of steam cured specimens was still higher than the
water cured ones; but the damage at 600 ⁰C got the higher percentage for steam cured
specimens. The damage level at 750 ⁰C and 900 ⁰C is much stronger than the 600 ⁰C
one. The peak load of SIFCON specimens was decreased approximately by 70% and 90% at
750⁰ C and 900 ⁰C, respectively. The importance of curing condition disappeared beyond
30
600 ⁰C exposure .It can be seen from the load–deflection curves of the SIFCON composites
subjected to the high-temperature that increasing parts of the curves were shifted to the right
This means that the stiffness loss occurred with an increase in temperature.
The modulus of elasticity and strength loss at 600, 750, and 900 ⁰C can be explained by a
few mechanisms. First of all, the detrimental effect of micro-cracks can be formed at the
areas of unhydrated grains and the Ca (OH)2 concentration. The decomposition of calcium
hydroxide (conversion of Ca (OH) 2 into CaO) can lead to damage as a result of lime
expansion during the cooling period. In addition, high temperatures especially above 400 ⁰C
lead to an increase in porosity, decomposition of hydration products, and destruction of
C–S–H structure Decomposition of the limestone aggregate and powders (CaCO3)around
750 ⁰C is another factor in terms of strength loss. Furthermore, the external surface of steel
fibers was covered by oxide film due to the high temperature. The oxidation causes a
decrement in cross section of steel fibers embedded in SIFCON.
As shown in Fig 13 the loss in the cross section of steel fibers becomes greater by increasing
the temperature. Besides, this phenomenon causes a significant decrement in fiber–matrix
bond strength. It is obvious that the thin concrete cover in SIFCON is an important
drawback in the case of the fibers near the surface. This situation must be considered for the
special applications.
Fig 13: Diameter loss in the cross section of steel fibers due to high temperature [5]
31
Fig 14: (a) Flexural strength (b) Toughness value of plain mortar [5]
The flexural strength and the toughness values of plain mortar are presented in Fig. 14. As
can be seen from Fig. 10a, flexural strengths of steam cured specimens are approximately
two times higher than the water cured ones. In addition, the flexural strength values were
decreased by 50–70% as a result of oven drying process. These behaviors are more
significant in the case of toughness values .Generally, the steam curing causes micro cracks
which can decrease the flexural strength of cement based mortars. However, this behavior is
not valid enough in this research due to a denser aggregate-matrix interfacial transition zone
that caused by incorporating the silica fume and GGBS.
The flexural strength and the toughness values of SIFCON specimens are presented in Fig.
11. As can be seen from Fig 10a, the flexural strength values of SIFCON composites are 5–
25 times higher than the plain mortar ones. The strength of specimens increased by 4–27%
at 300⁰ C. The maximum increase was observed in steam cured specimens. Furthermore, the
increase is lower in the case of oven-dried specimens. This behavior can be explained by
extra curing effect of saturated condition of SSD specimens at elevated temperatures. The
toughness values were increased in the same way as the flexural strength.
32
Fig 15 : (a) Flexural strength (b)Toughness of SIFCON specimen[5]
5.7 SUMMARY
The flexural strength values of SIFCON composites are 5–25 times higher than the plain
mortar ones according to the curing condition. Although the maximum load values
decreased by increasing exposure temperature, damaged SIFCON composites showed more
plastic behavior under flexure through fiber-slip mechanism.
33
CHAPTER 6
CONCLUSIONS
Following conclusions can be drawn about SIFCON
 Compressive strength was not affected by the use of waste steel fibers.
 Splitting and flexural strengths of the mixtures increased with higher amounts of
waste fibers.
 Binary cementitious blends of silica fume and ground granulated blast furnace slag
can be utilized effectively as an alternative source for cement, reducing the
consumption of cement, saving energy and environment.
 The optimum replacement level of silica fume and slag were found to be 15% and
30% respectively compared to all other replacement level. Slag based matrix shows
better performance of strength and durability characteristics.
 The damage level of reinforced SIFCON slabs subjected to impact loading is quite
less when compared to without conventional reinforcement.
 The flexural strength values of SIFCON composites are 5–25 times higher than the
plain mortar ones according to the curing condition.
 The plain specimens were exploded at temperature between 240 and 280⁰ C due to
narrow and discontinuous pore structure of matrix. On the other hand, explosion of
matrix phase due to high temperature was hindered by fiber inclusion (in the case of
SIFCON). Moreover, the flexural strength gain was observed in the case of 300⁰ C.
 The deterioration of flexural performance of SIFCON exposed to 600 ⁰C and higher
temperatures can be explained by the oxidation of external surface of steel fibers
which leads to decrease in the cross section of steel fibers and fiber–matrix bond
strength.
34
REFERENCES
[1] Sengul, O (2018) “Mechanical properties of slurry infiltrated fiber concrete
produced with waste steel fibers”, Construction and Building Materials, 186, 1082-
1091.
[2]Elevarashi, D and Mohan, R, S (2018) On low-velocity impact response of
SIFCON slabs under drop hammer impact loading, Construction and Building
Materials, 160,127-135.
[3]Al-Rousan, Z and Shannag, J, M (2018) Shear repairing and Strengthening of
Reinforced Concrete Beams Using SIFCON, Construction and Building Materials,
120,117-123.
[4]Jung, H., Park, S., Kim, S and Park, C (2017) Performance of SIFCON based
HPFRCC under Field Blast Load, Procedia engineering,201,401-408.
[5]Beglarigale, A., Yalcinkaya C., Yigiter H and Yazizi H (2016) Flexural
performance of SIFCON composites subjected to high temperature, Construction
and Building Materials,104,99-108.
[6] Ipek, M., Aksu M., Uysal M., Yilmaz, K and Vural ,I(2015) Effect of pre-
setting pressure applied flexure strength and toughness of new SIFCON + RPC
composite during setting phase, Construction and Building Materials,79,90-96.
[7]Tuyan, M and Yazici, H (2012) Pull-out behavior of single steel fiber from
SIFCON matrix, Construction and Building Materials,35,571-577
[8]Farnam, Y., Moosavi, M., Shekarchi, M., Babanajad, S, K and Bagherzadeh,
A (2010) Behaviour of Slurry Infiltrated fiber concrete under triaxial compression,
Cement and Concrete Research,40,1571-1581
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Performance of SIFCON as a Strengthening Material

1.1 SIFCON DESIGN PRINCIPLES

1.2 Factors affecting SIFCON efficiency

The following factors affect the strength of SIFCON.

1.3 Advantages of SIFCON

iii. SIFCON exhibits high ductility.

1.4 PREPARATION OF SIFCON

brief review on literatures of SIFCON as construction material is discussed below.

2.2 LITERATURES ON SIFCON

Elevarashi et al.(2018) explored the response of thin slabs of Slurry-Infiltrated Fibrous

Beglarigale et al. (2016) proposed high temperature resistance of SIFCON. High

Abdollahi et al. (2012) presents SIFCON strengthening as a new method of confinement in

3.2 MATERIALS USED

3.2.1 Cement and aggregate

Fig 1: Waste steel fibers used in the study [1]

Table 1: Mix Proportion of different mixes [1]

3.3 CASTING OF SPECIMENS

3.4 TESTING OF SPECIMEN

Compressive strength = load / area (N/mm2)

3.4.2 Split tensile strength

3.4.3 Flexure strength

3.5 RESULTS AND DISCUSSIONS

3.5.3 Flexure strength

3.5.4 Load-deflection curves

Fig 5: Load-deflection curve of SIFCON specimens [1]

PERFORMANCE OF SIFCON SLABS UNDER IMPACT LOADING

4.2 MATERIALS USED

4.2.2. Mineral admixtures

4.2.3. Fine aggregate

4.2.5. Steel reinforcement

4.2.8. Mix proportions

Table-2: Mix proportions of different mixes[2]

Type Mineral % Cement Silica Slag Sand Water SP Fibre

SIF 950.0 950 380 19 785

4.3.1 Casting of slabs without reinforcement

4.4 TESTING OF SPECIMEN

4.4.1 Compression test

Compressive strength = load / area (N/mm2)

4.4.3 Impact test

Fig 6: Drop weight impact test up[2]

4.5 RESULTS AND DISCUSSIONS

Type of mix Mineral % Compressive Split tensile

SIF 65.50 11.03

SIF SF 5 65.80 12.52

SIF SF 10 66.17 13.33

SIF SF 15 66.50 13.40

SIF SF 20 64.91 12.83

SIF SF 25 58.69 11.14

SIF S 15 67.25 14.67

SIF S 30 74.12 15.08

SIF S 45 68.75 14.78

SIF S 60 66.04 12.06

SIF S 75 59.73 11.98

Sl.No Type of Compressive Split No of blows required Blows

1 PCC(CS) 52.87 5.86 10

2 RCC(CS) 52.87 5.86 10 117 107

3 SIF(0) 65.50 11.03 246 1005 759

4 RSIF(0) 65.50 11.03 715 2364 1649

5 SIF(SF) 66.50 13.40 273 1032 759

6 RSIF(SF) 66.50 13.40 742 2572 1830

7 SIF(S) 74.12 15.08 303 1112 809

8 RSIF(S) 74.12 15.08 836 2740 1904