Faculty of Civil Engineering, Institute of Construction Materials, Prof. Dr.-Ing.

Viktor Mechtcherine

International Study Program ACCESS, 2014/2015

Module O-1: Building Materials

High performance Cement-based

High-performance Cement based Composites
Fibre Reinforced Concrete (FRC)
Viktor Mechtcherine
Institute of Construction Materials
 Introduction

History
y
S it b t /F
Spritzbeton/Faserspritzbeton
it b t
–Antic:
Faserspritzbeton Clay brick with straw and animals’ bristle
–
y France,, concrete with short steel pieces
End 19th century: p and steel fibres
for research purposes
1874 A. Berard: California, 1. Patent „Strengthening of concrete by the addition
of steel waste“
1887 Germany, 1. Patent

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine -2-

 Fibre types – Examples

Natural fibre Organic synthetics Inorganic fibre

Hemp Aramid Glass
Wood Carbon Steel
Cellulose Polyy acrylonitrile
y Ceramic
Polyethylene
Polypropylene
Polyy vinyl
y alcohol ((PVA))

• Short fibres • Continuous fibres (Filament) • Yarn, roving, Textile fabric

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine -3-
 Fibre types and their main properties
Fibre art Density Diameter Strength Young Modulus Strain Alkali re-
[‰] sistance
[g/cm3] [μm] [N/mm2] [N/mm2]
Steel fibre 7.8 200 - 1200 500 - 1500 200000 5 - 35 ++
AR glass 27
2.7 5 - 20 2000 - 4500 50000 - 110000 15 - 35 +
E glass 2.6 8 - 15 2000 - 4000 75000 20 - 35 –
Poly propylene 09
0.9 15 - 500 400 - 750 7500 - 18000 60 - 150 ++
Poly vinyl alcohol 1.3 13 - 300 800 - 1500 26000 - 36000 50 - 75 ++
Polyy acrylnitrile
y 1.2 13 - 100 600 - 1000 15000 - 20000 60 - 100 ++
Poly aramid 1.4 12 2700 - 3600 70000 - 130000 21 - 40 0
Polyester 1.4 10 - 50 800 - 1100 10000 - 19000 k. A. 0
Carbon 1.6 15 2200 - 4000 230000 20 ++
HF Carbon 1.9 9 550 - 750 30000 - 32000 10 ++
1.2 –
Cellulose 15 - 60 200 - 500 5000 - 40000 30 –
1.5
Sisal 1.5 10 - 50 800 k. A. k. A. –
Asbestos* 3.4 0.02 – 0.4 3500 200000 20 - 30 ++

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine -4-

 Ductility of concrete
– Performance and safety of the structure –

Effect of the ductility

y on the
structural behaviour
• Increase the bearing capacity under
static
t ti lload
d
 Redistribution of forces
 stress redistribution
 no concrete spalling
• Increase the structural safety
(advanced alarm of failure)

• High loading capacity under impact

loading
 Security
S it off structure
t t under
d hihigh
h
stresses
 Reduction in repair
p costs

Photos: Yoshimine (2001)

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine -5-
 Crack-control and structural behaviour

Steel reinforced concrete Steel reinforced concrete with fibres

Fischer (2005)

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine

 Ductility of concrete
– Durability of structures –
Typical damage
Effect of ductility on the
durability of structures

• Restriction of crack widths due to

stresses and external loads
 limitation of the penetration of Modell of reinforced concrete structure
liquids and gasses
 “self-healing effect” fine cracks

• Minimize the damage of structures Computational results

by means of corrosion processes
 Positive effect on the bearing
capacity, serviceability and the
appearance

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine -7-

 Crack-control and durability

Steel reinforced
concrete

10 mm

Steel reinforced
concrete with fibres

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine

 Effect of fibres on cracks distribution

without fibres with fibres

By the addition of fibres: - Inhibition of crack propagation

- Spreading in many
many, very fine,
fine “harmless”
harmless cracks

 under tension test : increase the tensile strength and/or the ductility
 under compression : improving the cracking behaviour and energy absorption
and tension

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine -9-

 Effect of fibres on fibre-bridging

Plain concrete Fibre reinforced concrete

no stress stress transmitting stress transmitting

crack crack crack

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 10 -

 Effectiveness of fibre reinforcement

Arresting
g crack p
propagation
p g g g the cracks
Bridging

More and finer cracks Transmitting the tensile stress by

through: fibres, restriction of crack widths,
increase the ductility and strength
• large amount of fibres
Fibres failure by means of:
• uniform fibre distribution
• fibre break
• good bonding matrix/fibre
• fibre pullout
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 11 -
 Fibres embedment length (under tension) in
dependency to their length

Tensile sttrength

Fibre length

For utilization of fibre tensile strength

strength, bonding length of lH is required
ft , F ft,F tensile strength of fibre
lH  d diameter of fibre
4 m d
m average of bonding stress
ft ,F
Critical fibre length lcrit   d
2 m
where  > 1 coefficient to consider the
crack position
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 12 -
 Performance – Relevant parameter

Critical fibre content VF,crit

F crit

1 f t ,M d
VF ,crit   
η τm l

C iti l fibre
Critical th lcrit
fib length
l
f t ,F
lcrit    d
2 m
ft,M strength of matrix
d fibre diameter
l g
fibre length
m average of bonding stress
 factor of fibre distribution (  1 )
ft,F
, strength of fibre
 coefficient to consider the crack position( > 1 )

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 13 -

 Fibre effect in tension

Low fibre content / Higher

g fibre content /
no optimal utilization of fibres optimal utilization of fibres

conventional fibre strain hardening fibre

reinforced concrete reinforced concrete

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 14 -

 Behaviour of steel fibre reinforced concrete
under uniaxial tensile tests

sttress in N/mm²²

strain in ‰
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 15 -
 Behaviour under compression

Influence of fibre content Influence of l/d value

smooth steel fibres, l/d=83 smooth steel fibres, vf= 2 Vol.%

stress N//mm²
essive stress N/mm²

comprressive s
compre

concrete concrete

compression strain mm/m compression strain mm/m

 an increase in l/d value or in fibre content will cause an increase

ultimate strain and fracture energy
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 16 -
 Performance – Relevant parameter

Effect of concreting´s
g direction
s N/mm²²
e stress

Tested in
“concreting” direction
pressive

2 Vol.% steel fibres

comp

Plain matrix – Tested perpendicular to

without fibres “concreting” direction

compression strain mm/m

Bolzen, Schmidt (1985)

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine

 Properties and stresses of fibres

Stress-strain curves Resistance of a tilted

fiber

AR glass Deflection force

mm²
strress in N/m

steel
Polyacrylnitrile
huge
curvature
Polypropylene w

strain in %

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 18 -

 Types of steel fibres, bonding properties

Common forms of steel fibres Results of pullout tests

Wire-short-cuts
straight

curved at the fibre’s end

Milld steel fibres

curved on the whole length

daN]
force [d
crushed on the whole length

crushed at the fibre’s end

Wire fibre with hooked ends  1 mm

manufacturing
straight

with deformed ends

deformation [mm]
Also as metal sheet stripes 1 daN = 10 N
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 19 -
 Fibre reinforced concrete – composition

Water-cement value
- w/c: 0.40 to 0.50
- relatively high cement content (workability !)
- usage of superplastisizer
- if necessary: replacement of approx. 30 % of cement by fly ash

Fibre content
- Steel fibres:
general : 0.5 to 2.5 Vol.-%
in situ : 0.25 to 1.0 Vol.-%
- Glass fibres : 1.5 to 4.0 Vol.-%
- Polymer fibres : 0.1 to 2.0 Vol.-%

Improving the bond of matrix/fibre by the addition of micro-silica

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 20 -

 Addition of fibres on mixing

Steel fibres Polymer

y fibres
(reference values acc. to “DBV-Sachstandsbericht”)
• addition to the finished concrete
(VF  1.0 Vol.-%, l/d < 100, grain-size  16 mm)
• addition to the “mortar part” before the addition of
aggregates
(VF  1.5 Vol.-%, l/d < 100, grain-size  16 mm)
• dry premix of polymer fibres + cement/fine
conventional concrete production
aggregates
t
(VF  1.0 Vol.-%, l/d < 200, grain-size  16 mm)

mixing time:
1 – 5 min after the addition of fibres

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 21 -

 Concrete matrix – composition & production

Grain-size and fibre distribution

• Aggregates which are larger than the average fibre spacing, lead to
an uneven fibre distribution
• Maximum grain-size should not exceed one-third of fibre length
(in steel fibre concrete)
• In case of glass fibre reinforced concrete/mortar:
maximum grain-size is 1 to 2 mm
• For HPFRC < 1 mm
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 22 -
 Mixing of fibre concrete

 Prevent “balling of fibres” ii.e.

e perfect dispersion of the added fibres
- Gluing with a water-soluble glue into bundles
- Separation
S ti off the
th componentst before
b f addition
dditi tot the
th mixture
i t b
by
sieving
- Influence
I fl parameters:
t l/d-ratio,
l/d ti fibre
fib content,
t t
fibre diameter, grain-size,
water content

 “Gentle” mixing of glass fibres

- short mixing
- rubber-coated mixing tools
- usage of small, round aggregates
- surface treatment of fibres

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine 23

 Arrangement & orientation of short fibres

Depending on the type of production and geometry of the component,

- in all directions (not oriented) (3 D)
- arranged
g in one p
plane only,
y, e.g.,
g , shotcrete ((2 D))
- a preferred direction (oriented), e.g., extruding (1 D)

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 24 -

 Relation between rheology and ductility

Effect of fibre addition on the flowability of self

compacting lightweight concrete (SCLC)
low amount of fibres

80 no increase in ductility

70
m]

l
large amountt off fibers
fib
Slump flow [cm

60

50 SCLC with steel fibres

SCLC with PP-fibres
40 blocking, poor de-
SCLC with
ith glass
l fib
fibres aeration
ti
30
0.0 0.2 0.4 0.6 0.8 1.0 optimum fibre content
Fibre content [Vol.-%]
high ductility,
self compacting

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine 25

 Relation between rheology and ductility

Test setup Experimental results

2.0

SCLC with 0
0.5
5 vol.-%
vol % steel fibres

1.5

mm²]
Tensile stresss  [N/m
1.0

LC with 0.5 vol.-% steel fibres

0.5
SCLC with 0.1 vol.-% PP-fibres
SCLC without fibres

0.0
0 0.05 0.10 0.15
Crack opening
p g w [mm]
[ ]

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 26 -

 Addition of fibres during dry-spraying process
Spritzdüse mit Zugabe der Stahlfasern für Stahlfaserspritzbeton

water ring

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 27 -

 Concrete composites and production

Considering
g the rebound
Fibres addition to the mixture Fibre content in the samples
[[kg/m³]
g ] [kg/m³]]
[kg/m

60 34

90 65
[Ding 2003]

Methods to reduce rebound: - increase cement content

- usage of fine substances

During the addition of fibres, the procedure can be done without

accelerator in order to ensure better cohesion of the mixture and higher
strength
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 28 -
 DAfStb-Guideline “Steel fibre-reinforced concrete”

Determination of stress and strain of steel fibre-reinforced concrete

L1

L2

35
3.5

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 29 -

 Determination of fracture behaviour
(DBV recommendation)
view cross section

fixed by
glue

transducer on
e sside
the de

load

F0.5  ffctR,L1
,

F3.5  ffctR,L2

F0.5
L1 = 0.5
0 5 mm ~  = 3.5
3 5 0/00
F3.5 L2 = 3.5 mm ~  = 25 0/00
0.5 3.5
deflection
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 30 -
 Stress-strain course due to DAfStb

3.5 0.1

Equivalent strength

ffctlm,L1 = F0.5 · l / (b · h²)  ffctR,L1

ffctlm,L2
tl L2 = F3.5
3 5 · l / (b · h
h²))  ffctR,L2
tR L2

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 31 -

 Determination of the facture behaviour acc. to
Rilem TC 162-TDF

Residual tensile strength

ffct,L = 1.5 FL · L / (b · hsp²) [N/mm²]

fR,i = 1.5 FR,i · L / (b · hsp²) [N/mm²]

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 32 -

 Stress-strain course acc. to
Brite Euram BRPR-CT98-0813

Characteristic

1 = 0.7 · ffct,L · (1.6 - d) [N/mm²]

3.5 2.0
2 = 0.45 · fR,1 · h [N/mm²]

3 = 0.37 · fR,4 · h [N/mm²]

1 = 1/ Ec

1.0 2 = 1 + 0,1 0/00

08
0.8
0.6
3 = 25 0/00
0.4
Ec = 9500 ·(fctm)1/3 [N/mm
[N/mm²]]
0.2

d = thickness [m]

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 33 -

 Behavior under cyclic-bending load

Flexural fatigue strength: bending strength after 10 million

number of cycles

Percentage of flexural fatigue strength at the flexural strength of static

short-term:

• unreinforced concrete 50 - 60 %
• steel fibre reinforced concrete 90 - 95 %
• poly propylene fibre reinforced concrete ca. 70 %

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine 34

 Creep and shrinkage

• Literature on creep and shrinkage of fibre reinforced concrete are

contradictory
• St
Steell fibres
fib hi
hinder
d shrinkage
hi k d
deformation
f ti and
d micro
i cracks
k ddue tto
stresses caused by shrinkage
 reduction of shrinkage
• Creep deformations in concrete are just little affected by steel
fibres
fib
- the stiffening effect of the fibres and the influence of the
present of high-content of compaction pores will equilibrate
each other
• polymeric
l i fib
fibres are used
d specially
i ll tto lilimit
it th
the crack
k fformation
ti iin
the setting process of concrete

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine 35

 Durability of fibre reinforced concrete

Steel fibres
• steel fibres corrodes when they are exposed to moisture and lying near the
surface of concrete
- rust stain will occur on the surface
- there is no concrete spalling because of the small diameter of the steel fibres
• steel fibre reinforced concrete samples, which were stored in see water, show
after 10 years an increase in strength
Polymer fibres
over the long-term behaviour of polymer fibres there are no negative
experiences
i
Glass fibres
- E-Glass fibres are inapplicable because of their poor alkali resistance
- even by AR glass fibres, lower strength and ultimate strain after many years
are expected

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 36 -

 Concrete damages because of fire

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 37 -

 Concrete damages because of fire

Pore pressure in concrete as a function of

temperature
e [N/mm²]
por pressure

Concrete spalling due to fire

vap

temperature [°C]

[König et al. 2003]

[Richter 1999]

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 38 -

 Fire resistance by the addition of fibres

Composition
p
- PP fibre content min. 2 kg/m³
- Fire resistance aggregates
gg g
(e.g. Magnesium-Silicate)
- Fibre “cocktail”: PP fibres and steel fibres

Example
- Aggregate 0/8 mm
- Cement 475 kg/m³ CEM III A 32.5
- Fly ash 25 kg/m³
kg/m
- Super plasticizer 1.4 % from cement mass
- Accelerator 4.5 % from cement mass
Streuli, Arge Transco Sedrun
- Additives 2.7 kg/m³ PP Fibres
(e.g. Duomix Fire M6, Bekaert) Installation of the fire resistance shotcrete
using a spry manipulator

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 39 -

 Fire resistance by the addition of fibres

Results
ace temperrature [°C]

RWS temperature-time curve

Average of furnace temperatures

Concrete with 0 kg/m³ PP fibres

furna

time [min]

[Dehn et al. 2006]

Concrete with 2 kg/m³ PP Fibres

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 40 -

 Advantages of fibre shotcrete

Positive effects of fibre addition

- pronounced improvement of ductility

- up to 30 % higher bending strength
- high strength after cracking
- improving the impact strength
- improving the adhesion strength
educt o o
- reduction of ea
early
y sshrinkage
age
- increase the fire resistance
- minimizing of crack widths in fibre reinforced concrete hinders the
transport processes (durability, serviceability)

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 41 -

 Applications of fibre reinforced concrete
– dynamically loaded structures –
Weir overflow
Advantages
g of fibre reinforcements
• structures in earthquake zones Cracking

• explosive structures
• elements with excess load
• impact protection structures weathering /
erosion
• structures under hydroabrasion
y
because of cavitations or wear by
coarse sediments
• coastal fortifications
• piles
p
• machine foundations

Hollow positions
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 42 -
 Further applications of fibre reinforced concrete

• L
Locall strengthening
t th i particularly
ti l l iin hi
highly
hl stressed
t d areas off steel
t l or
prestressed concrete components.
• S
Secondary
d b
barrier
i tto water-polluting
t ll ti substances.
b t Th
The fibres
fib d
decrease
the crack widths and thus limits the penetrations of such unfavorable
materials into the concrete.
• As steel fibre reinforced shotcrete in mining and tunneling.
• Thi
Thin-walled
ll d elements
l t ((no sufficient
ffi i t protection
t ti off steel
t l rebars
b b
by
concrete layer possible!).
• A
As repair
i material
t i l (mortar),
( t ) ffor example: l soil,
il ddams, b
bridges,
id f
facades
d
(also as spry mortar with glass or polymer fibres), structural elements
with high fire resistance (steel fibres).

TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 43 -

 Fibre reinforced concrete
– Standards,
Standards Regulations and Literature –

Steel fibre concrete Glass fibre concrete Fibre cement

- DBV-instructions: - DIN EN 15191 - DIN EN 492

Gl f
Glasfaserbeton,
b F i il
Fertigteile Faserzementdachplatten
steel fibre concrete, - DIN EN 1169
2001 Werkseigene - DIN EN 494
- Rili of DAfStb, 2010 Produktionskontrolle von Faserzementwellplatten
- DIN EN 13987-2 Glasfaserbeton - DIN EN 512
Stahlbetonfertiggara
Stahlbetonfertiggara- - DIN EN 1170
F
Faserzementdruckrohre
td k h
gen aus Stahlfaser- Prüfverfahren für
Glasfaserbeton - DIN EN 588
beton
- DIN EN 14649 Faserzementabwasser-
Faserzementabwasser
- DIN EN 1916
Beständigkeit von rohre
Stahlfaserbetonrohre Glasfasern im Beton - DIN EN 12467
- DIN EN 14888-7 - Friedrich,
Fi di h T T.:
Glasfaserverstärkter Faserzementtafeln
Fasergehalt von
Beton. Beuth, 2004
faserverstärktem
Spritzbeton
TU Dresden, Institute of Construction Materials, Prof. Dr.-Ing. V. Mechtcherine - 44 -