Fibre Concrete ( SFRC & PFC )

SAB 2112

Introduction

1.0 Introduction

The properties of unreinforced cement and concrete have been well document and an understanding of the basic principles of concrete technology has been assumed in writing the text. One of the problems of a cement-based matrix is the inherently brittle type of failure which occurs under tensile stress systems or impact loading and in the construction industry, a major reason for the growing interest in the performance of fibres in cement based materials is the desire to increase the toughness or tensile properties of the basic matrix.

Emphasis on energy conservation has also stimulated interest in methods of replacing materials such as cast iron, glass-reinforced plastics, and bituminous materials by the use of 1|Page

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fibre cement and fibre concrete. By replacing this existing materials, we able to satisfy the performance requirements of these various interests, adequate material properties must be achieved in the fibre composite and the main objective of engineers in attempting to modify the properties of cement or concrete are to improve the tensile or flexural strength, to improve the impact strength, to control cracking and the mode of failure by means of post-cracking ductility, and to change the rheology or flow characteristic of the material in the fresh state. ( D.J Hannat, 1978 )

It is now well established that one of the important properties of steel fibre reinforced concrete ( SRFC ) is its superior resistance to cracking and crack propagation. As a result of this ability to arrest cracks, fibre composites posses increased extensibility and tensile strength, both at first crack and ultimate, particular under flexural loading and the fibres are able to hold the matrix together even after extensive cracking.

Fibre reinforced concrete ( FRC ) may be defined as a composite materials with Portland cement, aggregate, and fibres. Plain, unreinforced concrete is a brittle material with low tensile strength and a low strain capacity. The role of fibre is to brigde across the cracks that develop provides some post cracking ductility . if the fibres are sufficiently strong, sufficient bonded to materials, and permit fibre reinforced concrete to carry significant stresses over a relatively large strain capacity in the post cracking stage.

There are many ways of increasing the strength of the concrete. The real function of concrete is to increase the toughness of the concrete under any type of loading. That is the fibres tend to increase the strain and peak load and provide a great deal of energy absorption in post-peak portion between the load versus deflection curve. When the reinforcement is in the form of short discrete fibres, they act as rigid inclusions in the concrete.

The strength of fiber-reinforced concrete are not significantly greater than same mixes were we used without the fibers. The resulting concretes, are together and have the greater resistance to cracking and higher impact resistance. The use of fibers has increased the

versatility of concrete by reducing its brittleness. The improvement obtained in the toughness of concrete by adding fibers is dependent on the fibers aspect ratio that is length and diameter and most typically the aspect ratios used vary from about 25 up to as mush as 150, with 100 being about an average value. ( Jack C. McCormac , 2005 ) 2|Page

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Properties of Materials

2.1 Properties of Fibres and Matrices

The main factors controlling the theoretical performance of the composite materials are the physical properties of fibers and the matrix and the strength of the bond between two. The modulus of elasticity of the fiber is generally less than five times that the matrix and this combined with the low fiber volume fraction means that the modulus of composite is not greatly different from that of the matrix.

The fibres can be divided into two main groups , that are cellulose, nylon and polypropylene with lower moduli while the other group with high moduli such as asbestos, 3|Page

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glass, steel, carbon, and Kevlar, which is a form of aromatic polyamide introduced by DuPont. The last two are included for the sake of completeness but high cost seem to rule them out for major engineering applications.

The low modulus of fibers are generally subject to relatively high creep which means that if they are used to support permanent high stresses an a cracked composite, considerable elongations or deflections may occur over a period of time. They are more likely to be used in situations where the matrix is expected to be uncracked but overloads such as handling stresses, impacts or wind loads are significant. Another problem with low moduli fibers are they have large values of Poissons ratio means that if stretch along their axis, they contract sideways much more than the other fibers. This will leads to a high lateral tensile stress at the fiber matrix interface which is likely to cause a short aligned fiber to debond and pull out. Other devices such as woven meshes or fibrillated fibers may therefore be necessary to give efficient composites.

Even the high modulus fibers may require mechanical bonding to avoid pull out unless the specific area is very large. This steel fibers are commonly produced with varying crosssectional to provide anchorage and glass fiber bundles may be penetrated with cement hydration products to give an effective mechanical bond after a period of time.

The maximum particles of size also important because its affects the fiber distribution and the quantity of fibers which can be included in the composites. Actually, the average particles size of cement paste before hydration is between 10 and 30 microns where the mortar is considered to contains aggregate particles up to 5 mm maximum size. Concrete to be intend to be used in conjunction with fibers should not have particles greater than 20 mm and not greater than 10 mm otherwise uniform fiber distribution becomes difficult to achieve.

To avoid shrinkage and surface problems in finished products it is advisable to use at least 50 percent by volume of mineral filler, which may be aggregate or could include pulverized fuel ash, or limestone dust. If the inert filler consists of a large volume of coarse aggregate, the volumes of the fibers which can be included will be limited that will turn limit the tensile strength and ductility of the composite. 4|Page

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Strength of the matrix is affected by the free water or cement ratio and this parameter also has a lesser effect on the modulus. The value of fiber density are important and enable the relationship between fiber volume which is required for the theoretical treatment and the fiber weight.

The commercial viability of fiber composites is critically dependent on the costs of the fibers which controlling influence on the cost of the product because the matrix is so cheap. A commercial decision on existing product can be profitably replace with one made from fibre cement or fibre concrete may depend on using the cheapest and suitabale fibre to fulfill the strength and durability equipments.

Unfortunately, it is not possible to give specific prices because costs of fibres are subject to rapid change depending on demand and energy costs in their production. The cost may have be taken regarding saving in labour or transport costs compared with the cost of equivalent products in timber, steel, aluminium, plastic, or reinforced concrete before these new materials are use in large quantities.

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Steel Fibre Reinforced Concrete

3.1 Steel Fibres

The uses of steel fibre have mainly been in conjunction with concrete or mortar and has been placed on the production of the thin sheets products which form the bulk of the asbestos cement or glass fibre cement industries. Steel is most commonly used

materials for the fibres. Fibresteel is used generally for high flexural fatigue strength, high wear resistance requirements, precast applications and so on. Steel fibres come in many shapes and sizes each with different performance levels. To make a true comparison between different products and ensure the correct selection is made, it is recommended that

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each potential supplier be asked to supply accredited test results for their products in accordance with one of the internationally recognised standards.

Picture 1 : Steel Fibre

3.2

Mix Design for Steel Fibre Reinforced Concrete ( SFRC )

As with any other type of concrete, the mix proportions for SFRC depend upon the requirements for a particular job, in terms of strength, workability, and so on. Several procedures for proportioning SFRC mixes are available, which emphasize the workability of the resulting mix. However, there are some considerations that are particular to SFRC.

In general, SFRC mixes contain higher cement contents and higher ratios of fine to coarse aggregate than do ordinary concretes, and so the mix design procedures the apply to conventional concrete may not be entirely applicable to SFRC. Commonly, to reduce the quantity of cement, up to 35% of the cement may be replaced with fly ash. In addition, to improve the workability of higher fibre volume mixes, water reducing admixtures and, in particular, superlasticizers are often used, in conjunction with air entrainment. For steel fibre reinforced shotcrete, different considerations apply, with most mix designs being arrived at empirically. A particular fibre type, orientation and 7|Page

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percentage of fibers, the workability of the mix decreased as the size and quantity of aggregate particles greater than 5 mm increased; the presence of aggregate particles less than 5 mm in size had little effect on the compacting characteristics of the mix. Figure 1 shows the effects of maximum aggregate size on workability.

The second factor which has a major effect on workability is the aspect ratio (l/d) of the fibres. The workability decreases with increasing aspect ratio, in practice it is very difficult to achieve a uniform mix if the aspect ratio is greater than about 100.

3.3 Technology for Producing Steel Fibre Reinforced Precast Concrete ( SFRC )

SFRC can, in general, be produced using conventional concrete practice, though there are obviously some important differences. The basic problem is to introduce a sufficient volume of uniformly dispersed to achieve the desired improvements in mechanical behaviour, while retaining sufficient workability in the fresh mix to permit proper mixing, placing and finishing. The performance of the hardened concrete is enhanced more by fibres with a higher aspect ratio, since this improves the fibre-matrix bond. On the other hand, a high aspect ratio adversely affects the workability of the fresh mix. In general, the problems of both workability and uniform distribution increase with increasing fibre length and volume.

One of the chief difficulties in obtaining a uniform fibre distribution is the tendency for steel fibres to ball or clump together. Clumping may be caused by a number of factors:

I.

The fibres may already be clumped together before they are added to the mix; normal mixing action will not break down these clumps.

II. III. IV. V.

Fibres may be added too quickly to allow them to disperse in the mixer. Too high a volume of fibres may be added. The mixer itself may be too worn or inefficient to disperse the fibres. Introducing the fibres to the mixer before the other concrete ingredients will cause them to clump together.

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In view of this, care must be taken in the mixing procedures. Most commonly, when using a transit mix truck or revolving drum mixer, the fibres should be added last to the wet concrete. The concrete alone, typically, should have a slump of 50-75 mm greater than the desired slump of the SFRC. Of course, the fibres should be added free of clumps, usually by first passing them through an appropriate screen. Once the fibres are all in the mixer, about 30-40 revolutions at mixing speed should properly disperse the fibres. Alternatively, the fibres may be added to the fine aggregate on a conveyor belt during the addition of aggregate to the concrete mix. The use of collated fibres held together by a water-soluble sizing which dissolves during mixing largely eliminates the problem of clumping. SFRC can be placed adequately using normal concrete equipment. It appears to be very stiff because the fibres tend to inhibit flow; however when vibrated, the material will flow readily into the forms. It should be noted that water should be added to SFRC mixes to improve the workability only with great care, since above a w/c ratio of about 0.5, additional water may increase the slump of the SFRC without increasing its workability and place ability under vibration. The finishing operations with SFRC are essentially the same as for ordinary concrete, thought perhaps more care must be taken regarding workmanship.

3.4 Structural Use of Steel Fibre Reinforced Precast Concrete ( SFRC ) As recommended by ACI Committee 544, when used in structural applications, steel fibre reinforced concrete should only be used in a supplementary role to inhibit cracking, to improve resistance to impact or dynamic loading, and to resist material disintegration. In structural members where flexural or tensile loads will occur .. the reinforcing steel must be capable of supporting the total tensile load. Thus, while there are a number of techniques for predicting the strength of beams reinforced only with steel fibres, there are no predictive equations for large SFRC beams, since these would be expected to contain conventional reinforcing bars as well. An extensive guide to design considerations for SFRC has recently been published by the American Concrete Institute. In this section, the use of SFRC will be discussed primarily in structural members which also contain conventional reinforcement.

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For beams containing both fibres and continuous reinforcing bars, the situation is complex, since the fibres act in two ways:

I.

They permit the tensile strength of the SFRC to be used in design, because the matrix will no longer lose its load-carrying capacity at first crack; and

II.

They improve the bond between the matrix and the reinforcing bars by inhibiting the growth of cracks emanating form the deformations (lugs) on the bars.

However, it is the improved tensile strength of SFRC that is mostly considered in the beam analysis, since the improvements in bond strength are much more difficult to quantify. Steel fibres have been shown to increase the ultimate moment and ultimate deflection of conventionally reinforced beams; the higher the tensile stress due to the fibres, the higher the ultimate moment.

3.5 Applications of Steel Fibre Reinforced Precast Concrete ( SFRC )

The uses of SFRC over the past thirty years have been so varied and so widespread, that it is difficult to categorize them.The most common applications are pavements, tunnel linings, pavements and slabs, shotcrete and now shotcrete also containing silica fume, airport pavements, bridge deck slab repairs, and so on. There has also been some recent experimental work on roller-compacted concrete (RCC) reinforced with steel fibres. The list is endless, apparently limited only by the ingenuity of the engineers involved. The fibres themselves are, unfortunately, relatively expensive; a 1% steel fibre addition will approximately double the material costs of the concrete, and this has tended to limit the use of SFRC to special applications.

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Picture 2 :Steel Fibre Reinforced Concrete

Picture 3 : Steel Fibre Reinforced Precast Concrete

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Polypropylene Fibre Concrete

4.1 Polypropylene Fibre Today it is very common to add polypropylene fibres into concrete for strengthening concrete and for protection of concrete against micro cracks. Most common count for this application is a PP with a relatively short cut of 12 mm. Other cuts used but less common are 6, 18 and 24 mm. The function of the PP fibre mixed into concrete is not to replace the steel but to avoid the creation of micro cracks in the concrete. Fibres are coated with spinning oil to improve wetting, improve dispersion within the cement paste, increase the extent of contact and improve bond to the hardened concrete.

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The fibres are manufactured in a continuous process by extrusion of polypropylene. The extruded material is heated, stretched to improve tensile strength, coated with spinning oil and cut to the required lengths. The manufacturing process includes control checks on heating and cooling temperatures, operating speeds and pressures, stretch ratio and quality of cut and stretching. Quality assurance checks are conducted on spinning oil content, moisture content, weight and denier. The fibres are packed in measured quantities in dispersible paper bags, suitable for 1 m3 of concrete. The bagged fibres are delivered in cardboard boxes. Boxes of fibres must be stored on a clean surface, in dry conditions under cover and away from the possibility of damage. Each box bears the manufacturer's and product name, batch number.

Picture 4 : Polypropylene Fibre Mesh

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Picture 5 : Polypropylene Fibre

4.2 Applications of Polypropylene Fibre Concrete ( PFC )

Most of this Polypropylene Fibre Concrete ( PFC ) are used for our needed in construction nowdays. There are many uses like :

I. II. III. IV. V. VI. VII. VIII. IX. X.

Most small builder, cas sales dan DIY applications Internal floor-slabs ( retail stores,warehouses ) External slabs ( driveways ) Agricultural applications Roads, pavements, kerbs Shortcrete : thin section walling Overlays, patch repair Water retaining structures, marine applications Safety applications like strongrooms Deep lift walls

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4.3 Mix Design for Polypropylene Fibre Concrete ( PFC )

To use polypropylene fibers this is basically all the concrete worker must know. Concrete mix design does not have to be altered, and no special equipment or slump modifications are required, even for pumping or shotcreting. Only two things must be determined: how much fiber to add and what length of fiber to use. Polypropylene fibers are manufactured in small bundles that look like miniature sheaves of straw.

The bundles are fibrillated, which means they are made of many small fibers. During the mixing operation,the movement of aggregate shears these bundles into smaller bundles and individual fibers. Fibrillated fibers reportedly do not cling together or ball. One manufacturer also makes a single-filament fiber for use in prepackaged dry mortar mixes. These fibers are 14 and 12 inch long. They are not added to alreadymixed concrete. As already described, adding the premeasured bag of fibers for every cubic yard of concrete. fiber is simple one

Fibers are packaged in the amount recommended by the manufacturer for use in 1 cubic yard of concrete. Recommendations vary. One manufacturer recommends 3 pounds of fiber per cubic yard of concrete (or 0.2 percent by volume) for most applications; other manufacturers recommend about 112 pounds per cubic yard (or about 0.1percent fiber by volume) .

If the jobsite is less than a 30-minute drive from the concrete plant, the fibers can be added at the plant along with the cement and aggregate. If the jobsite is farther than a 30-minute drive, the fibers should be added at the site. When used in high-slump mixes or cellular lightweight concrete mixes or when mixed in turbine mixers, additional mixing time may be necessary.

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4.4 The Effects on Concrete

ASTM Committee C09.03.04 and ACI Committee 544 are both now in the process of developing standard tests for measuring the properties of fiber reinforced concretes. Until such tests are standardized, reported results will vary depending on the test method used. Some of these present tests may not accurately describe the behavior of fiber reinforced concretes in field installations. Based on the research that has been done, though, some of the effects polypropylene fibers have on the properties of concrete are described here. As noted, testing research is ongoing.

4.5 Effects on The Properties of Hardened Concrete

In hardened concrete, polypropylene fibers act as crack arresters.

Like any

secondary reinforcement, the fibers tend to stop cracks from propagating by holding the concrete together so cracks cannot spread wider or grow longer. However, since polypropylene fibers are distributed throughout the concrete, they are effective close to where cracks start at the aggregate paste interface. The fibers thus form a sort of threedimensional reinforcement that distributes tensile stresses more evenly throughout the concre t e. According to tests now beingreviewed by ASTM C09.03.04, this three dimensional reinforcement results in improved impact resistance, particularly in the impact resistance to ultimate failure. Flexural strength and tensile strength are also improved, each about 10 percent. The compressive strength of concrete that has undergone its potential drying shrinkage is about the same for concrete with or without Polypropylene fibers. The ductility of concrete is said to be improved too because of polypropylenes low modulus of elasticity.

4.6 Features and Benefits

The addition of fibres helps to maximize the intrinsic early strength of the concrete. For the future, we can improve the concretes resistance to plastic shrinkage cracking. Then, it is inhibits formation of micro-cracks due to dimensional change and it can reduces sedimentation. 16 | P a g e

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The benefit of this PFC are it can reduced frequency of plastic cracking. That is why this PFC is suitable for safety application like strongrooms. Other than that, it can improved durability and reduced permeability and also can cut the construction cost. Finally, this PFC will decrease risk of plastic settlement cracking over re-bar.

Picture 6 : Polypropylene Fibre Concrete

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Conclusion

Nowdays, there are many new and modern technologies in upgrading all construction materials. The main purpose are want to increase the strength and make it as high workability product. As long as it can save the environment, we can use it. By replacing this existing materials, we able to satisfy the performance requirements of these various interests, adequate material properties must be achieved in the fibre composite and the main objective of engineers in attempting to modify the properties of cement or concrete are to improve the tensile or flexural strength, to improve the impact strength, to control cracking and the mode of failure by means of post-cracking ductility,

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and to change the rheology or flow characteristic of the material in the fresh state. ( D.J Hannat, 1978 )

Fiber-reinforced concrete used in structural applications requires characteristic material properties that can be easily incorporated into existing design procedures. This paper investigates the postcracking response of reinforced concrete tension members made with both plain and steel fiber-reinforced concrete ( SFRC ). Loading was either monotonic or cyclic, and shrinkage effects are included in analysis of the member response. Tension-stiffening results are used to determine the average tensile response of concrete after cracking, and an expression is developed to predict this smeared behavior as a material property for cracked SFRC, as well as to estimate crack spacings. Specimens with steel fibers exhibited increased tension stiffening and smaller crack spacings, which both contributed to a reduction in crack widths. The postcracking tensile strength of fiber concrete at the cracks is the determining factor affecting behavior and is a fundamental material property used to predict tension stiffening and crack behavior for conventionally reinforced SFRC. The uniaxial strength of SFRC immediately after cracking governs serviceability behavior, while the postcracking strength at larger deformations governs strength design and is responsible for tension stiffening after yielding of the reinforcement. Cyclic loading did not have a significant effect on either tension stiffening or crack width control for the specimens tested.

Rational use of fiber-reinforced concrete ( FRC ) in structural applications requires a consistent approach to design that incorporates material properties that are relevant to the types of analysis typically used for reinforced concrete. The main advantage of using fibers in oncrete is to improve the postcracking response,and for this reason the postcracking tensile strength is a material property most appropriate for design with FRC.

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REFERENCES

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D.J Hannat (1978),Fibre Cement and Fibre Concrete, John Wiley & Sons, Inc. George C. Hoff ( 1984 ), Fiber Reinforced Concrete International Symposium, American Concrete Institute. Jack C. McCormac, Jack K. Nelson ( 2005 ), Design of Reinforce Concrete Sixth Edition, John Wiley & Sons, Inc. K. H. Tan and M. A. Mansur, Shear Transfer in Reinforced Fiber Concrete Journal of Material in Civil ASCE Vol. 2,No. 4, November, 1990 Nguyen Van CHANH, Steel Fiber Reinforced Concrete - Faculty of Civil Engineering, Ho Chi Minh City University of Technology. Peter H.Bischoff ( 2003 ), Tension Stiffening and Cracking of Steel FiberReinforced Concrete - Journal of Material in Civil ASCE / MARCH/APRIL 2003.

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