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Fibre-reinforced cements
42.1 42.2 42.3 42.4 42.5 Asbestos cement Glass-reinforced cement (GRC) Natural bres in cement Polymer bre-reinforced cement References
through roofs when not using the required crawling boards. The net result of these adverse factors has been to virtually eliminate sales of asbestos cement products in Europe and the USA but nevertheless there is still more asbestos cement on structures throughout the world than all other types of bre cement combined and therefore a detailed description of its properties is warranted herein.
FIGURE 42.2 Hatschek manufacturing process for asbestos cement sheeting. FIGURE 42.1 Asbestos bre bundle in cement paste after natural weathering for more than 10 years.
26 24
320 m2/kg) is used to minimise ltration losses. Referring to Figure 42.2, in very much simplied terms, the Hatschek machine operates as follows. A dilute slurry pours into the vat and drains through a porous sieve cylinder depositing the solid contents as a layer on the surface of the sieve. The water passes through the sieve surface and returns to the vat via the backwater circuit. The sieve cylinder rotates and the layer rises out of the vat. A continuous felt runs in a loop from the sieve cylinder to an accumulation roll. Surface tension forces the layer to transfer from the top of the sieve cylinder to the underside of the felt. The movement of the felt transfers the layer from the sieve to the accumulation roll and on the way it is vacuum dewatered. Typical outputs are 1 tonne per hour per metre width of vat. Felt speeds range from 40 to 70 metres per minute. A typical three-vat machine will make a 6 mm thick sheet in six to nine revolutions and will make one sheet every 20 seconds. Manufacturing costs are therefore very low. Due to the process, the bres are essentially dispersed in two directions with the predominant alignment of the bres in the direction of rotation of the sieve drum. The stacks of products may reach 60C and autoclaving is sometimes used to reduce the shrinkage of the products.
20 Stress (MPa)
16
12
600
1800
2200
Tensile
stressstrain
curve
for
42.1.2 Properties
Asbestos cement is the only bre composite for which there are International Standards requirements for certain properties. These are generally expressed in terms of minimum bending strength, density, impermeability and frost resistance. For instance, the minimum bending strength generally varies between 15 MPa and 23 MPa when tested under dened conditions and depending on whether the sheet is semi- or fully compressed.
Also, various loading requirements are dened for corrugated sheets such as snow loads up to 1.5 kPa, and point loads to simulate men working on a roof. Water absorption should not exceed 20 to 30 per cent of the dry weight depending on the type of product. A typical tensile stressstrain curve for a commercial product is shown in Figure 42.3 where the failure strain is about 2000 106. No cracks were visible before failure which may be controlled by crack suppression as described in Section 41.2. A modulus of elasticity of about 20 GPa in tension and compression and a modulus of rupture well in excess of 30 MPa have combined to provide probably the most successful example of all time of a bre-reinforced composite both in terms of tonnage and protability.
to replace natural slate. Asbestos cement pressure pipes have been used for many years for conveying mains water, sewage, sea water, slurries and industrial liquors. Diameters range from 50 mm to 900 mm with working pressures from 0.75 MPa to 1.25 MPa. It is the extraordinary ability of the asbestos bres to suppress cracking in the matrix which has made these watertight applications possible and no other bre cement has been able to emulate its performance. Also, non-pressure uid containers such as rainwater goods, conduits, troughs, tanks and ue pipes have accounted for a large proportion of the minor applications of asbestos cement.
42.1.3 Durability
Asbestos cement is known to be very durable under natural weathering conditions and little deterioration in exural properties takes place due to weathering, although the material becomes progressively more brittle. However, it has been shown that asbestos bres in cement sheets at ages of 2, 16 and 58 years do suffer a certain amount of corrosion which is compensated for, in terms of composite strength, by an increase in bond between the bre and the cement. The corrosion of the bre is promoted by the penetration of airborne carbon dioxide which causes carbonation at the surface of the bre. Also, certain magnesium hydroxides and carbonates may be formed as reaction products. The natural variability in bre strength tends to mask any measured changes in bre strength due solely to weathering.
42.1.4 Uses
Corrugated roong and cladding for agricultural and industrial buildings has formed by far the largest application, and the ability to be moulded into complex shapes has enabled a wide range of accessories to be produced for roong applications. Flat sheet has been used for diagonal tiles
about 0.35, workability aids and, typically, 3 per cent by weight of 12 mm long bres. Having been mixed, the composite may be cast by pumping with or without vibration and also by spraying. Pressing combined with dewatering may also be used with premixes. Prebagged formulations containing between 0.5 per cent and 2.5 per cent by weight of glass bre have also been developed for rendering brickwork or blockwork. As with all cement-based products, it is important to moist cure glass-reinforced cement products for as long as possible to ensure that a maximum amount of hydration and hence strength gain has occurred before loading.
FIGURE 42.4 Glass bre strand in cement paste.
FIGURE 42.5 Tensile stressstrain curves of spray dewatered glass-reinforced cement (Oakley and Proctor, 1975).
42.2.3 Durability
In the 1970s, the durability of GRC was found to be strongly inuenced by the environment to which it was exposed (Majumdar et al., 1991) For instance, in dry air, there was little change in exural or tensile strength during a 10-year period, whereas under water or in natural weathering there was a decrease in tensile strength of the composite by more than 50 per cent. The decrease in impact strength was even more severe, reducing by an order of magnitude. The changes were due to a combination of factors including a
loss in bre strength and failure strain due to alkali attack, and an increase in matrix cracking stress due to continuing cement hydration which increases the critical bre volume above the included bre volume. Another contributing factor was the lling of the voids in the bre bundles with lime crystals and calcium silicate hydrates which increased the bond with individual glass laments so that matrix cracks easily propagated through the bre bundle. The net result of these changes was to reduce the composite strain to failure, in some cases to matrix failure strain, thus reducing the once ductile material to a brittle material. An example of the way in which the increase in matrix strength and reduction in composite strain to failure can affect the critical bre volume and toughness of the composite is shown below using Figure 42.6. For glass-reinforced cement, the following values have been published (Building Research Establishment, 1979): 28 days, Ec 22.5 GPa with a bend-over point at 9.5 MPa, which gives mu 422*106, fu 1000 MPa; 10 years, Ec 28.5 GPa, no accurate value for the bend-over point is given. If we assume no change in mu and take fu equal to 600 MPa after 10 years, equation (41.3) gives an increase in Vfcrit from 1 per cent at 28 days to 2 per cent at 10 years for aligned bres. Most glass-reinforced cement is sprayed with short bres in a random (2-D) orientation. To
Typical Cem-FIL GRC design stresses for different manufacturing methods (from trade literature) Loading example compressive cylinder hoop stress bending of sandwich panels bending of box sections or channels bending of solid beams or plates shear loading Hand or premix 12 MPa 3 MPa 4 MPa 6 MPa 1 MPa Machine spray 12 MPa 2 MPa 2.5 MPa 4 MPa 1 MPa
Note: These design values may be varied in certain product areas, e.g. formwork. Limit state methods are also used.
take account of the non-alignment, we multiply the value of fu by 0.27 (the efciency factor for stress) and nd that a total bre volume fraction of more than 3.5 per cent at 28 days, and more than 7.4 per cent at 10 years is required to maintain ductility. Typical total bre volumes are about 4 per cent and it is known that the energy absorbed to failure, found from the area under the measured stressstrain curve, reduces from about 120 kJ/m3 at 28 days to less than 5 kJ/m3 at 5 years. This change may therefore be explained by the increase in critical bre volume with time. An understanding of these potential problems resulted in research to eliminate calcium hydroxide growth by including a metakaolin synthetic pozzolana (described in Chapter 15) to react with the free lime in a controlled way to prevent lime build up within the bre bundle. The metakaolin particles also appear not to migrate into the bre bundle. Results from these modied matrices using accelerated tests have indicated that greatly improved durability and long-term toughness of GRC composites should now be possible using about 25 per cent cement replacement by metakaolin. Thus, long-term stable properties for metakaolin-based matrices approximate to curve A in Figure 42.6 rather than the embrittled curve type B. In contrast, silica fume with a particle size of less than 0.1 micron, although reacting with the lime, may penetrate to individual laments and result in the formation of hard calcium silicate hydrates which are as damaging to the bres as lime deposition. However, a note of caution should be made regarding the long-term predictive ability of hightemperature accelerated tests because, as with many durability problems with cement-based materials, total condence can only be gained by real time trials in natural weathering conditions over many years.
42.2.4 Uses
Cladding panels are a major eld of application for glass-reinforced cement. Due to cracking caused by restrained warping in early applications particular attention should be paid to
thermal and moisture movements and to xing details in large, double-skinned sandwich panels of this type of construction. Light colouring of the panels is preferred because this helps to reduce thermal stresses particularly where there is an insulating core. There is increasing emphasis on the use of single-skin cladding panels attached to prefabricated steel frames by exible anchors. This is known as a GRC Stud Frame system. The xings are designed to allow unrestrained thermal or moisture movements of the glass-reinforced cement skin which may be 6 m long by storey height. An important use where the early age strength and toughness are benecial is in permanent formwork for bridge decks, the advantage being that no temporary support works are required and a dense, high-quality cover is provided to the reinforcement. The greater efciency ensured by using continuous glass bre rovings in the main stress direction has been utilised in a process for producing corrugated sheeting. The corrugated sheets start as a continuous at sheet made from two layers, each 3.25 mm thick. Short strands as cross reinforcement are immersed in the matrix on the upper/underside and this leads to an ideal sand-
wich structure. The lengthwise reinforcement is mostly made up of one-directional inlaid glass bre rovings, which are sandwiched between the two layers that make up the sheet. The at sheets are then corrugated on formers before curing. There are many other uses such as cable ducts, agricultural products, sewer linings, culverts, sound barriers, drainage channels, re-resistant boards, septic tanks, roong slates and mortar renders for dry block wall construction. Some trials have been made using glass bre tendons protected with polyester resin as prestressing tendons in prestressed concrete structures.
that the properties of the composite may vary considerably from dry to wet. The bres are used in volumes up to 10 per cent in conjunction with polymer bres in asbestos-free products in which manufacturing procedures are very similar to the Hatschek process already described for asbestos cement. Properties When suitably pre-treated by rening, wood bres used in conjunction with polyvinyl alcohol bres in a matrix of Portland cement and llers can provide a tough and durable bre cement. This composite is suitable for the commercial production of corrugated sheeting and pressed tiles on traditional slurry dewatered systems such as the Hatschek machine (Figure 42.2). The variation in composite properties wet to dry and pressed to unpressed is shown in typical tensile stressstrain curves for commercial composites in Figure 42.7. Uses In Australia, cellulose bres have completely replaced asbestos bres in at sheeting products made from an autoclaved calcium silicate. Autoclaved systems are said to have the advantage over air-cured hydrated cement binders in that there is greater dimensional stability in relation to moisture and temperature movements. Also because of the absence of free alkalinity the boards can be more easily decorated. In the UK, at sheet for internal and external applications has been available for a number of years, produced from cellulose bres in an autoclaved calcium silicate matrix. A wide range of properties is available in cellulose bre boards, typical values being an elastic modulus of 12 GPa with the tensile strength varying between 6 MPa and 20 MPa and the modulus of rupture between 15 MPa and 30 MPa depending on whether the composite is wet or dry and on the bre volume. Typical tensile stressstrain curves in the dry and wet states for these materials are shown in Figure 42.8.
FIGURE 42.7 Effect of moisture condition on the tensile properties of a cement composite containing cellulose bres and articial bres pressed, unpressed.
Effect of moisture condition on tensile properties of autoclaved calcium silicate containing cellu-
Wood cellulose bres in concrete Wood cellulose bres are not suitable for use in bulk concrete applications because of difculties in mixing and compaction and their use is therefore limited to automated factory processes. In some of these processes wood chips or akes at up to 20 per cent are mixed with cement and ne sand to make a variety of compressed wood chip boards or particle boards. These are generally
used internally and have low exural tensile strength, often below 1 MPa. They are not strictly bre-reinforced cements.
based roof sheeting often of corrugated or folded plate design. Long bres which are indigenous to the locality are used, such as akwara, banana, bamboo, coir, elephant grass, ax, henequen, jute, malva, musamba, palm, plantan, pineapple leaf, sisal, sugar cane and water reed. Lengths of bres may be up to 1 m or more and are hand placed in a matrix of sand and cement. Corrugated sheets of up to 2 m by 1 m in size of 610 mm thickness and tiles may be produced with bres in preferential directions. Manufacture and applications Composites made from vegetable stem bres are manufactured by simple hand lay-up processes which are potentially suitable for low-cost housing applications. In these applications the bre content is usually less than 5 per cent when applying mixing technologies, but it may be greater when using the technologies of hand lay-up of long bre rovings. Hand laying involves the application of a thin mortar layer on a mould, followed by alternate layers of bres and mortar matrix. The bres can be rolled into the matrix or worked into it manually, and the process may involve some vibration. In the mixing technique, there is a limit to the content and length of bres that can be incorporated, since as with any other bres workability is reduced. However, many of the natural bre composites are intended for the production of thin components such as corrugated sheets and shingles, and for these applications there is a requirement for both plasticity and fresh strength that will permit the shaping of the product. For such purposes, reduced ow properties are not as detrimental as in the case of conventional concrete. In these components, which have a typical thickness of about 10 mm, the matrix is a cement mortar, and the mix with bres, or with handlaid bres, is spread on a mould surface and then shaped. Corrugation can be achieved by pressing between two corrugated sheets.
Properties The cracking stress and strength of the composites are not greatly increased compared with the unreinforced matrix (i.e. about 1 MPa to 3 MPa) but the bres enable the sheets to be formed in the fresh state and handled and transported in the hardened state. Considerable toughness is achieved in the short term. Bamboo, when split into strips and woven into meshes, has been used as reinforcement for a variety of applications from roads and structures to water tanks. Tensile strengths of the bre are commonly in excess of 100 MPa with elastic moduli between 10 and 25 GPa. Toughening and post-cracking performance are the most important characteristics and optimum bre volumes between 1.5 per cent and 3 per cent have been quoted. Durability The high alkalinity of the pore water prevents microbiological decay in the bres but, to set against this, the calcium hydroxide penetrates the bre to mineralise or petrify it. The high alkalinity can cause severe reduction in bre strength but where carbonation has penetrated, this rate of reduction of strength is reduced. However, natural stem bres are not expected to give the composite a long lifetime, although short cellulose bres as used in alternatives to asbestos cement products have been shown to be more durable than natural stem bres.
bres will be substituted for the asbestos bres. It is clear therefore that there is a potential market and considerable inroads have been made since the early 1980s by polymer bres into this industry. Although a wide variety of polymers has been used on a trial basis in cement-based materials, only a few have been commercially successful. Polypropylene and polyvinyl alcohol have been the most used although polyethylene pulp is also used in some thin sheet products.
each bre is enhanced by the presence of the other bre. Manufacture The continuous networks are laid up in two directions in twelve-layer packs. Three or four packs are fed simultaneously to a machine which impregnates them with cement slurry in sequence, producing a wet, at sheet with good twodimensional strength. This is then corrugated in a vacuum corrugator. Both chopped and continuous glass bres can be included in the process. Properties All the requirements for roong sheet can be met and additionally, toughness values of 1000 kJ/m3 are possible. The failure strain remains in excess of 5 per cent after weathering, provided that the critical bre volume is exceeded at the appropriate age. Durability Polypropylene bres show excellent resistance to alkalis and in a cement matrix have been shown to have good resistance to a variety of weathering
300
200 Natural weathering 150 95% confidence limits 100 Under water 50 Laboratory air
0 0 5 Time (years) 10 15 20
FIGURE 42.10
conditions up to 18 years of real time exposure (Figure 42.10). Equally important is that the bond strength has been shown to be time stable up to 18 years (Hannant, 1999), giving condence in the long-term toughness of polypropylene bre composites.
42.5 References
Ali, M.A., Majumdar, A.J. and Singh, B. (1975) Properties of glass bre cement the effect of bre length and content. J. Materials Science, 10, 173240. Bentur, A. and Mindess, S. (1990) Fibre Reinforced Cementitious Composites, Elsevier Applied Science, London and New York.
Hannant, D.J. (1999) The effects of age up to 18 years under various exposure conditions on the tensile properties of polypropylene bre reinforced cement composites. Materials and Structures, RILEM, 32, March, 838. Oakley, D.R. and Proctor, B.A. (1975) Tensile stressstrain behaviour of glass bre reinforced cement composites. In Fibre Reinforced Cement and Concrete, Construction Press Ltd, Lancaster, UK, pp. 34759. Swamy, R.N. (ed.) (1988) Natural Fibre Reinforced Cement and Concrete, Vol. 5, Concrete Technology and Design, Blackie, Glasgow.