properties of polymer concrete
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Properties of Polymer Concrete
Polymer concrete may be poured as slabs for large projects.
Polymer concrete uses binders, such as epoxies (glues),
polyester, or resins, to bind the concrete together. The addition
of binders gives polymer concrete greater resistance to corrosion
than conventional Portland cement. Polymer concrete, composed
of water, finely crushed stone or gravel, sand and a binder,
makes an excellent mortar for filling gaps between bricks, tiles
and cement blocks.
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1. Basics
Polymer cement comes in a variety of colors; tan and gray
are the most common. For large projects, this material is usually
sold as a liquid, which is then poured into a frame. he material
cures !dries and hardens" fully after seven days.
Polymer cement may be used around the home to patch masonry
wor#. For smaller projects, it is usually sold at home
improvement stores in a premi$ed buc#et or as a %&'lb. bag ofpowder that must be mi$ed by hand. Polymer concrete has a
liquid wor#ing temperature between (& F and )% F. he ma$imum
wor#able temperature of this type of concrete is 1%& F.
*. +trength
+trength is an important characteristic of concrete, as it is
often used as a structural foundation material. Polymer concrete
has an average compressive strength between 1&,&&& and
1*,&&& pounds of pressure per square inch !P+". -$act
compression strength varies depending upon the brand of
polymer concrete and what type of material is used as a binder.
ompressive strength increases over time. Polymer /ethyl
/ethacrylate oncrete has compressive strength of ),&&& P+
after one hour of setting and 1*,&&& P+ after seven days of
setting.
0. orrosion
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Polymer concretes main advantageous property is its
resistance to a wide range of solvents and oils; it is also resistant
to acids with a p2 level ranging from & to 13. Polymer concrete is
resistant to a variety of acids that can eat away concrete over
time, including soda and potash lye, ammonia, hydrochloric acid,
formic acid, acetic acid, chlorides and ammonium sulfate. Polymer
concrete does not corrode in the presence of hydrocarbons, such
as acetone, gasoline, ethane, methanol, petroleum, diesel and
vegetable oils. his type of concrete offers e$cellent resistance
against water.
Fle$ibility
raditional concrete is vulnerable to shearing forces that can
cause crac#s and a decline in structural integrity. 4esistance to
these forces is #nown as fle$ural and tensile splitting strengths.
o give concrete the ability to e$pand and contract without
crac#ing, it is poured on a rebar frame.
Polymer concrete offers greater resistance to crac#ing. Polymer
concrete has a fle$ural strength between 0,35& and 0,5*6 P+
after eight hours. ensile strength is between 1,)&& and *,&13
P+ after the material has been allowed to set for seven days.
Properties and Applications of Fiber Reinforced
Concrete
Fiber Types
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Fibers are produced from different materials in various shapes
and si7es. ypicalfiber materials are8*,01;
Steel Fibers
+traight, crimped, twisted, hoo#ed, ringed, and paddled ends.
9iameter rangefrom &.*% to &.5(mm.
Glass Fibers
+traight. 9iameter ranges from &.&&% to &.&1%mm !may be
bonded together toform elements with diameters of &.10 to
1.0mm".
Natural Organic and Mineral Fibers
:ood, asbestos, cotton, bamboo, and roc#wool. hey come in
wide range ofsi7es.
Polypropylene Fibers
Plain, twisted, fibrillated, and with buttoned ends.
Other Synthetic Fibers
evlar, nylon, and polyester. 9iameter ranges from &.&* to
&.0)mm.< convenient parameter describing a fiber is its aspect
ratio !=9", defined as thefiber length divided by an equivalent
fiber diameter. ypical aspect ratio ranges fromabout 0& to 1%&
for length of ( to 5%mm.
Mixture Copositions and Placing
/i$ing of F4 can be accomplished by many methods
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he mi$ should have auniform dispersion of the fibers in
order to prevent segregation or balling of the fibers during
mi$ing. /ost balling occurs during the fiber addition process.
ncrease ofaspect ratio, volume percentage of fiber, and si7e and
quantity of coarse aggregatewill intensify the balling tendencies
and decrease the wor#ability. o coat the largesurface area of the
fibers with paste, e$perience indicated that a water cement ratio
between &.3 and &.(, and minimum cement content of
3&&#g>m80? are required. ompared to conventional concrete,
fiber reinforced concrete mi$es are generallycharacteri7ed by
higher cement factor, higher fine aggregate content, and smaller
si7e coarse aggregate.< fiber mi$ generally requires more
vibration to consolidate the mi$. -$ternal vibration is preferable
to prevent fiber segregation. /etal trowels, tube floats, and
rotating power floats can be used to finish the surface.
Copressi!e Strength
he presence of fibers may alter the failure mode of
cylinders, but the fiber effectwill be minor on the improvement of
compressive strength values !& to 1% percent".
Modulus of"lasticity
/odulus of elasticity of F4 increases slghtly with an
increase in the fibers content. t was found that for each 1
percent increase in fiber content by volume there is
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an increase of 0 percent in the modulus of elasticity.
Flexure
he fle$ural strength was reported to be increased by *.% timesusing 3 percentfibers.
Toughness
For F4, toughness is about 1& to 3& times that of plain concrete.
Splitting Tensile Strength
he presence of 0 percent fiber by volume was reported to
increase the splittingtensile strength of mortar about *.% times
that of the unreinforced one.
Fatigue Strength
he addition of fibers increases fatigue strength of about 6&
percent and 5& percentof the static strength at * $ 1&(
cycles for non'reverse and full reversal of loading, respectively.
#pact Resistance
he impact strength for fibrous concrete is generally % to 1&
times that of plain concrete depending on the volume of fiber
used
Corrosion ofSteel Fibers
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< l@'year e$posureof steel fibrous mortar to outdoor weathering
in an industrialatmosphere showed no adverse effect on the
strength properties. orrosion was
found to be confined only to fibers actually e$posed on the
surface. +teel fibrous
mortar continuously immerse in seawater for 1& years e$hibited a
1% percent loss
compared to 3& percent strength decrease of plain mortar.
+tructural Behavior of F4
Fibers combined with reinforcing bars in structural members will
be widely used in
the future. he following are some of the structural behaviour
( )l
A .
Fle$ure
he use of fibers in reinforced concrete fle$ure members
increases ductility, tensile strength, moment capacity, and
stiffness. he fibers improve crac# control and
preserve post crac#ing structural integrity of members.
orsion
he use of fibers eliminate the sudden failure characteristic of
plain concrete
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beams. t increases stiffness, torsional strength, ductility,
rotational capacity, and
the number of crac#s with less crac# width.
+hear
<ddition of fibers increases shear capacity of reinforced concrete
beams up to 1&&
percent. <ddition of randomly distributed fibers increases shear'
friction strength,
the first crac# strength, and ultimate strength.
olumn
he increase of fiber content slightly increases the ductility of
a$ially loaded specimen. he use of fibers helps in reducing the
e$plosive type failure for columns.
2igh +trength oncrete
Fibers increases the ductility of high strength concrete. he use of
high strength
concrete and steel produces slender members. Fiber addition will
help in controlling
crac#s and deflections.
rac#ing and 9eflection
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ests86? have shown that fiber reinforcement effectively controls
crac#ing and deflection, in addition to strength improvement. n
conventionally reinforced concrete
beams, fiber addition increases stiffness, and reduces deflection.
<pplications
he uniform dispersion of fibers throughout the concrete mi$
provides isotropic
properties not common to conventionally reinforced concrete. he
applications of
fibers in concrete industries depend on the designer and builder
in ta#ing advantage
of the static and dynamic characteristics of this new material. he
main area of F4
applications are11&1 A
4unway, <ircraft Par#ing, and Pavements
For the same wheel load F4 slabs could be about one half the
thic#ness of plain
concrete slab. ompared to a 05%mm thic#ness of conventionally
reinforced concrete slab, a 1%&mm thic# crimped'end F4 slab
was used to overlay an e$isting as'Properties and <pplications
ofFiber 4einforced oncrete %0
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phaltic'paved aircraft par#ing area. F4 pavements are now in
service in severe and
mild environments.
unnel =ining and +lope +tabili7ation
+teel fiber reinforced shortcrete !+F4+" are being used to line
underground openings and roc# slope stabili7ation. t eliminates
the need for mesh reinforcement and
scaffolding.
Blast 4esistant +tructures
:hen plain concrete slabs are reinforced conventionally, tests
showed!llj that
there is no reduction of fragment velocities or number of
fragments under blast and
shoc# waves. +imilarly, reinforced slabs of fibrous concrete,
however, showed *&
percent reduction in velocities, and over )& percent in
fragmentations.
hin +hell, :alls, Pipes, and /anholes
Fibrous concrete permits the use of thinner flat and curved
structural elements.
+teel fibrous shortcrete is used in the construction of
hemispherical domes using the
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inflated membrane process. lass fiber reinforced cement or
concrete !F4" ,
made by the spray'up process, have been used to construct wall
panels. +teel and
glass fibers addition in concrete pipes and manholes improves
strength, reduces
thic#ness, and diminishes handling damages.
9ams and 2ydraulic +tructure
F4 is being used for the construction and repair of dams and
other hydraulic
structures to provide resistance to cavitation and severe errosion
caused by the impact of large waterboro debris.
@ther <pplications
hese include machine tool frames, lighting poles, water and oil
tan#s and concrete repairs.
omparative +tudy of the /echanical Behavior of F4
Csing =ocal /aterials
4esearches are being carried out in the ivil -ngineering
9epartment of ing <bdula7i7 Cniversity about the mechanical
properties of fibrous concrete and the structural behaviour of
fibrous concrete beams with and without prestressing subjected
to
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different combinations of bending, shear, and torsion. < study of
the mechanical behavior of fibrous concrete using local materials
is presented in this section.
/aterials
able 1shows the different properties of the straight and the
hoo#ed fibers used in
this study. he hoo#ed fibers are glued together into bundles with
a watcr'stlluh#
adhesive. he collating of the 0& fibers createD an artificial aspect
ratio ot appro$i'%3 Faisal Fouad :afa
mately 1%. he plain fibers were obtained by cutting galvani7ed
steel wires manually.
ype portland cement, l@mm graded crushed stone aggregate,
desert sand offineness modulus 0 .1, and a 0 percent super
plastici7er were used for all the mi$es. he
mi$ proportion was 1.&A*.&A1.( and the water'cement ratio was
&.33.
<B=- 1. Properties of straight and deformed steel fibers.
+traight fiber 2oo#ed fiber
/aterial alvani7ed +teel arbon +teel
=ength !mm" %0.&& (&.&&
9iameter !mm" &.51 &.)&
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<spect ratio !=9" 5%.&& 5%.&&
f>/Pa" *(&.&& ((&.&&
:or#ability
he conventional slump test is not a good measure ofwor#ability
of F4. he inverted slump cone test !*.3" devised especially for
the fibrous concrete is recommended. he time it ta#es an
inverted lamp cone full of F4 to be emptied after a
vibrator is inserted into the concrete is called the inverted'cone
time. t should vary
between 1& and 0& seconds.
he conventional slump test !<+/ 30'5)" and the inverted
slump cone test
!<+/ 66%')0" were conducted to compare the performance of
the plastic concrete reinforced with the two different types of
fibers. he hoo#ed fibers performed
well during mi$ing because no balling occurred even though the
fibers were added to
the mi$er along with the aggregate all at one time. he straight
fibers had to be
sprin#led into the mi$er by hand to avoid balling. t too#
appro$imately * minutes to
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add the straight fibers to the mi$, resulting in a * minutes e$tra
mi$ing time. Figure 1
shows the effect of fiber content on both slump and inverted cone
time. t is clearly
seen that as the fiber content increased from &.& to *.& percent,
the slumps value decreased from *0& to *&mm, and the time
required to empty the inverted cone time increased from *& to 5&
seconds. For the highest fiber volume percentage used !Ef
*.& percent" it was noticed that the F4 in the test specimens
was difficult to consolidate using the internal vibrator.
ompressive +trength
+i$ty concrete cylinders !1%&& $ 0&&mm" were cast and tested in
compression
!<+/ 06" at the end of5, *) and 6& days. Figure * shows the
effect of the hoo#ed
fiber content on the compressive strength values and shows the
stress'strain relationship. he fiber addition had no effect on the
compressive strength values. 2owever,
the brittle mode of failure associated with plain concrete was
transformed into a
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more ductile one with the increased addition of fibers. Figure 0
presents the effect ofProperties and <pplications ofFiber
4einforced oncrete
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F. 0. -ffect of hoo#ed fiber content on compressive strength at
different ages.
hoo#ed fiber content on the compressive strength after 5, *) and
6& days. t is observed that although slight scatter e$ists, the
percentage of fiber volume content has
practically no influence on the compressive strength of concrete
either at early or
later stage of its life. able * and Fig. 3 present a comparison of
the strength for
hoo#ed and straight fibers which indicates that the fiber types
and content have little
effect on the compressive strength. he results are similar to
those of other investigators8*,01.
<B=- *. omparison of strengths using hoo#ed and straight
fibers !5 days" .
' .
ompressive +trength /odulus of 4upture +plit ensile +trengh
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F. 3. ompressive, fle$ural and splitting strengths for hoo#ed
and straight fibers !5 days".
/odulus of-lasticity
Figure * shows that the initial slope of the stress'strain curve is
practically the same
for all mi$es and equal to 01,6&& /Pa compared to 0&,3&& /Pa
obtained using the
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< formula. his indicates that the modulus of elasticity does not
change much by
the addition of fibers.
Fle$ural estS /odulus of4upture
+i$ty concrete beams !1&& $ 1&& $ 0%&mm" were tested in
fle$ure !<+/ 5)'
5%" after 5, *) and 6& days. Figures % and ( show the load'
deflection curves for
hoo#ed and straight fibers with different volume content. he
load'deflection curve
for plain as well for fibrous concrete is linear up to point < !Fig. %"
and the strength
at < is called the first crac#ing strength. For plain concrete
beams, crac#ing immediately leads to failure. Beyond point <, the
curve is non'linear due to the presence of fibers and reaches the
ultimate strength at B. <fter reaching the pea# value,
the fle$ural strength drops and attains a steady value of (& to 5&
percent of the pea#%)
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F. (. =oad'deflection curves for straight fibers.Properties and
<pplicatioll+ ofFiber 4einforced @llcrele %6
value in the case of hoo#ed fibers. For straight fibers, the fle$ural
strength goes on
dropping until failure, showing continous slippage of the straight
fiber. his behaviour can be e$plained as follows. For the fibrous
concrete, once crac#s are initiated, the fibers start wor#ing as
crac# arresters. Cse of fiber produces more closely
spaced crac#s and reduces crac# width. <dditional energy is
required to e$tend the
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crac#s and debond the fibers from the matri$. he deformed ends
of the hoo#ed fibers contributed significantly to the increase in
the bond between fiber and matri$ and
e$tra energy is required for straightening the deformed ends
before a complete debonding can ta#e place.
Figure 5 shows the effect of hoo#ed fiber content on fle$ural
strength after 5, *)
and 6& days. he addition of 1.% p rcent of hoo#ed fibers gives
the optimum increase
of the fle$ural strength. t increased the fle$ural strength by (5
percent, whereas the
addition of *.& percent straight fiber gives the optimum increase
of the fle$ural
strength by 3& percent more than that of the plain concrete
!compared to the *%& percent increase given in literature*1 u
ing 3 percent fibers". <t a high dosage of hoo#ed
fiber !* percent", the test specimens were difficult to consolidate
and fibers were
probably not randomly distributed. his caused a slight reduction
in strength. able
* and Fig. 3 show the comparison between the two fibers.
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+plitting eos2e +trength
+i$ty concrete cylinders !1%& $ 0&&mm" were tested for splitting
strength !<+/
36(" after, 5,*) and 6& days. Fig. ) shows the effect of hoo#ed
fiber addition on the
splitting tensile strength. t is clear that the highest improvementis reached with 1.%
percent fiber content !%5 content more than plain concrete".
able * and Fig. 3 show
the comparison between hoo#ed and straight fibers.
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F. ). -ffect of hoo#ed fiber content on splitting tensile strength
at different ages.
oughness !-nergy <bsorption"
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oughness as defined by the total energy ab orbed prior to
complete separation of
the specimen is given by the area under load'deflection curve.
oughness or energy
absorption of concrete is increased considerably by the addition of
fibers. he toughness inde$ is calculated as the area under the
load deflection curve !Fig. %" up to the
1.)mm deflection divided by the area up to the first crac#
strength !proportional
limit". he calculated toughness inde$ for each mi$ isiven in
able 0. <ll specimens
made of plain concrete failed immediately after the first crac#
and, hence, th toughness inde$ for these specimens is equal to
1. he addition of fiber increases the toughness inde$ of hoo#edand straight fibers up to 16.6 and 1(.6, respectively. he average
toughness inde$ for pecimens reinforced with hoo#ed fibers wa
*% to (% percent greater than that for specimens reinforced with
straight fibers.Properties and <pplications ofFiber 4einforced
oncrete
<B=- 0. -ffect of fiber content on the toughness inde$.
Fiber content!O"
oughness nde$
2oo#ed fibers +traight fibers
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&.& 1.& 1.&
&.% 11.3 6.*
1.& 1).& 11.1
1.% 16.6 10.(
*.& 1(.5 1(.6
(1
mpact +trength
Fifteen short cylinders !1%&mm diameter and (0mm thic#" were
cast and tested for
impact
l3? after *) days. he results of impact test are given in Fig. 6.
he rest results
show that the impact strength increases with the increase of the
fiber content. Cse of
* percent hoo#ed fiber increased the impact strength by about *%
times compared to
1& times given in literature8*1.
3&&&''''''''''''''''''''''
0(&&
01&&
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*(&&
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F. 6. -ffect of hoo#ed fiber content on the impact strength.h*
Faisal F@llad :afa
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onclusion
Based on the test of one hundred and ninety five specimens
made with the available local materials, the following conclusions
can be derivedA
1. Go wor#ability problem was encountered for the use of hoo#ed
fibers up to 1.%
percent in the concrete mi$. he straight fibers produce balling at
high fiber content
and require special handling procedure.
*. Cse of fiber produces more closely spaced crac#s and reduces
crac# width. Fibers bridge crac#s to resist deformation.
0. Fiber addition improves ductility of concrete and its post'
crac#ing load'carrying capacity.
3. he mechanical properties of F4 are much improved by the
use of hoo#ed
fibers than straight fibers, the optimum volume content being 1.%
percent. :hile fibers addition does not increase the compressive
strength, the use of 1.% percent fiber
increase the fle$ure strength by (5 percent, the splitting tensilestrength by %5 percent, and the impact strength *% times.
%. he toughness inde$ of F4 is increased up to *& folds !for 1.%
percent hoo#ed
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fiber content" indicating e$cellent energy absorbing capacity.
(. F4 controls crac#ing and deformation under impact load much
better than
plain concrete and increased the impact strength *% times.
he material covered by this investigation mainly is concerned
with the mechanical properties of F4 using local materials.
4esearches are being conducted in the
ivil -ngineering laboratory of ing <bdula7i7 Cniversity on the
structural behavior of F4 members.
4eferences
8? 4amualdi, I.P. and Batson, .B., he /echanics of rac#
<rrest in oncrete, Iournal of the -ngineering /echanics 9ivision,
<+-, )6A135'1() !Iune, 16)0".
8*I <- ommittee %33, +tate'of'the'<rt 4eport on Fiber
4einforced oncrete, < oncrete nternational, 3!%"A 6'0&
!/ay, 16)*".
80? Gaaman, <.-., Fiber 4einforcement for oncrete, <
oncrete nternational, 5!0"A *1'*% !/arch,
16)%".
83? < ommittee %33, /easurement of Properties of Fiber
4einforced oncrete, !< %33.*4'5)",
<merican oncrete nstitute, 9etroit, 5 p. !165)".
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8%? 2alrorsen, ., oncrete 4einforced with Plain and 9eformed
+teel Fibers, 4eport Go. 9@'+
5('*&. Federal 4ailroad <dministration, :ashington, 9.., 51 p.
!<ug., 165(".
8(? raig, 4.I., +tructural <pplications of 4einforced Fibrous
oncrete, < oncrete nternational,
(!1*"A *)'0*0 !16)3".
85? <bdul':ahab, 2./.+., <'<usi, /.<. and awtiq, +.2., +teel
Fiber 4einforced oncrete/embers
under ombined Bending, +hear and orsion, 4=-/ ommittee
36'F4 +ymposium, +heffield,
-ngland !16)(".
8)? raig, 4.I., /connell, I., ermann, 2., 9ib, G. and ashani,
F., Behavior of 4einforced Fibrous
oncrete olumns, < Publication +P')1A (6'1&% !16)3".
86? +wamy, 4.G., <'aan, +. and <li, +.<.4., +teel Fibers for
ontrolling rac#ing and 9eflection,
< oncrete nternational, 1.!)"A 31'36 !1656".
81&? 2enger, .2., :orldwide Fibrous oncrete Projects, <
oncrete nternational, 5!6"A 10'16
!16)1".
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!? :illiamson, .4., 4esponse of Fibrous'4einforced oncrete to
-$plosive =ading, C.+. <rmy -ngineer. 9ivision, echnical 4eport
Go.