SYNTHETIC FIBER REINFOCED CONCRETE

BY FAWAD UL HAQ SUBMITTED TO Dr. AMJAD NASIR Department Of Civil Engineering University of Engineering And Technollogy Peshawar

INTRODUCTION
Concrete is a brittle when subjected to tensile stresses, it cracks. Concrete may already be crack before applying load because of shrinkage or thermal effects. For this reason steel reinforcement has been used to overcome the low concrete tensile strength. As a composite system, the reinforcing steel is assumed to carry all tensile load. Another approach to limit concrete brittleness concern the used of discontinuous fibers to produce fiber reinforced concrete. In fiber reinforced concrete thousands of small fibers are dispersed and randomly distributed in the concrete matrix, therefore, they improve concrete properties in all direction. Fibers enhance the post cracking strength in tension, the fatigue strength the resistance to impact loading and reduce temperature and shrinkage cracking. fibers reinforced concrete finds application in many area of civil engineering where needs for repairing and durability arises. Fiber used in concrete may be natural or synthetics.in this project we will only discuse the types, properties, and effect on concrete of synthetics fibers only.

SYNTHETIC FIBERS:
Synthetics fibers are primarily developed by the petrochemicals and textile industry. Synthetic fibers are nonmetallic fibers including polymers that are available in a variety of formulations. Synthetic fibers are added to concrete before or during mixing operation. The use of synthetic fibers of typical addition rate does not require any mix design change.

TYPES OF SYNTHETICS FIBERS:

There are different types of synthetics fibers but the most commonly used are:

1. Polypropylene:

it is manufactured from the homopolymer polypropylene resin.

These fibers have a low modulus of elasticity and also a low melting point. Low melting point of this fiber may be beneficial when used in fire resistance structure, because the fibers are expected to melt and provide a system of relief channels to dissipate internal pressure. Polypropylene fibers are hydrophobic, so they do not absorb water and have no effects on concrete mixing water requirement. Polypropylene may be fibrillated bundles or monofilament. to produce fibrillated fibers manufacturer extrude the polypropylene in sheet that are stretched and silt. The result is a mesh of interconnected fibers strands rectangular in cross section. Manufacturers cut the strands to specified length and separate them into bundles. Fibers length range from to 2 inches.when added to concrete during mixing, the fibrillated fibers open into a network of linked fibers filament that mechanically anchor to the cement paste. Sometime graded fibrillated fibers are also used. Graded fibrillated fibers have various length, size, and fibrillation patterns. The graded fibers disperse more thoroughly into all areas of the cement paste during mixing. Monofilament fibers are fine, cylindrical strands that separate during mixing because monofilament fibers are smooth and have a small surface area they don not anchor into the cement matrix as well, as fibrillated fibers. With fibrillated fiber, cement paste penetrate into the network of fibers filament resulting in better mechanicals anchoring to the concrete. Research show that lower volume of fibrillated fibers than of monofilament fibers are needed to improve the post cracking load carrying capacity and ductility of concrete. Monofilament fibers are good for relative short term benefits, such as plastics shrinkage , cracks control during the first few hours after concrete placement.

2. POLYESTER:
Polyester fibers are available in monofilament form in length from to 2 inches. Like polypropylene, polyester fibers are hydrophobic. However, they have a tendency to disintegrate in alkaline environment of Portland cement concrete. To retard this degradation, manufacturer coat the fibers to resist alkali attack. Polyester are temperature sensitive and above normal service temperature their properties may be altered.

3. NYLONE:
It is present only in monofilament form, unlike polypropylene and polyester it is hydrophilic. It retains a moisture balance of 4.5%. Because of this strong affinity to water, nylone fibers bond chemically to the concrete matrix. The bond of polypropylene and polyester is only mechanical. Nylone fibere also have higher aspect ratio than those of polypropylene. Therefore, it can be added in small dosage to produce the same reinforcing effect. These fibers also exhibit good tensile strength, high toughness and excellent elastic recovery.

4. CORBON: Corbon fibers are inert in nature these fiber have high modulus, thermal
resistance and long term chemicals stability in alkaline and other chemically aggressive environment . it is also improve mechanical properties.

5. POLYVINYL ALCOHOL:
Polyvinyl alcohol (PVA) fibers are manufactured from PVA resin . A special surface treatment allows for improved fibers dispersion in cementetious system. Unfortunately PVA fibers have a negative coefficient of thermal expansion, shrinking 4% in length at 200C. PVA is generally resistant to alkaline and organic solvent.

TWO TYPES OF SYNTHETIC FIBER: MACRO VS MICRO:

There are two classes of synthetics fibers, macro fiber and micro fibers. 1.

MICRO FIBERS:
Micro fibers are usually with diameter less than 0.1mm. It is used at low addition rate, usually below 0.1% by volume of concrete. Microfibers are used to reduce plastics shrinkage cracking in concrete before hardens.

2.

MACRO FIBERS:
Macro fibers also called, structural synthetics fibers, are design to control crack in harden concrete. These fibers are used to at high rate upto 1% by volume of concrete, which provide increased flexural toughness, impact resistance and fatigue

resistance to harden concrete. Fig 1f shows two examples of latest synthetic structural fibers of blended polypropylene and polyethylene with different length and aspect ratio, the composition and configuration of which are design to achieve optimal performance for flooring and tunnel lining application respectively.

PROPERTIES OF SYNTHETIC FIBERS:

Several different kinds of polymers have been investigated for their suitability for used in concrete. In evaluating fibers the following aspect are of interest:

1) MECHANICAL PROPERTIES:
Fibers mechanical properties determine its potential as concrete reinforcing materials. Table 1 gives the properties of synthetics fibers used to reinforced concerete . Except polyaramid synthetics fibers are characterized by low modulus of elasticity and high elongation. Low modulus of elasticity of the fiber means that high strength composite are not achievable with synthetic fibers. Their advantages lies in increasing such properties as strain capacity, toughness and crack control, properties that are more important for slab construction than strength.

TABLE 1: SYNTHETICS FIBERS PROPERTIES

2) PHYSICAL PROPEERTIES:
Table 1 also gives the physical properties of synthetics fibers. The fibers are characterized by low density so that a low mass of fibers yield a high volume of fibers in concrete. polymerics fibers are also very flexible, therefore, fiber breakage or mechanical distortion, will not be a problem during concrete. The relative low thermal stability of polymer could be disadvantage. melting point are generally below 300C but service temperature are considerably lower, since the fiber start to soften and loose their tensile properties at temperature considerably below the melting point .t this behavior causes loss of reinforcing capabilities in structured exposed to high temperature (e.g. fire). The glass transition temperature represent change in consistency from rubbery to brittle as the temperature is lowered. It should also be considered.

3)

CHEMICAL PROPERTIES:

Cement paste developed a moist alkaline environment, dangerous to many organic materials. The minimum pH in cement paste is about 12.3. howeve many modern cement have high alkali(sodium and potassium) content, which can raise the pH to 13.5 or greater when the cement is mixed with water. This high pH is detrimental to some polymers. Polester, polyacrylics and polyamids are particularly sensitive so they can undergo alkaline hydrolysis. Hydrolysis may be slow at room temperature, but may be significantly accelerated at higher temparture. In studies on polyacrylic fibers slight loss of strength at 20C was also observed after 2 months. By contrast , the hydrophobic nature of polypropylene and polyethylene makes them quit resistant to alkaline condition. However these fibers are sensitive to oxidation, particularly in the presence of sunlight and are treated with anti-oxidant to reduce this succeptibilty.

4) FIBERS GEOMETRY AND DIMENSION:

Fibers are availables in many different geometry and dimension. Three different types of fibers are available: 1.

MONOFILAMENT:
Monofilaments are usually single straight fibers made by drawing molten polymers. Such fibers are usually round in cross-section , ranging in diameter from 50 m to 0.5 mm. such fibers are usually strong since the drawing process tends to align the polymers chains and induce crystallization, but smooth surface may result in a low interfacial bond strength, which limits the reinforcing capability of the fibers.

2.

ROVING:
Many polymers are spun in the form of filament whose dia varies from 5 to 15m. several thousands fibrils are spun simultaneously, by drawing them from a single die and bundle together. The bundle is held intact either by sizing materials or by twisting them into yarn. Roving are cut into short length (<2 inch) when adding them into concrete in concrete. The yarn separate into individuals fibrils, which dispersed efficientltly During mixing. Dispersed rovings acts as individual monofilament within the cement matrix.

3.

FIBRILLATED POLYMERS:

Fibrillated polymers are formed by splitting a polymers film longitudinally and then cut it into suitable length and width, so that the fibers can be considered as bundles of cross linked fibrils. When pull apart the fibrillated fibers opens out into a mesh of connected fibrils. The geometry of a fibrillated fiber can be described in term of the film thickness (generally 15 to 100 m) and width of each fibril (100 to 600 m). This form of fibers is limited to film forming polymers (polypropylene and polyethylene). During mixing, the bundles are opend up by the aggregate to act as individuals fibrils, that each contribute to the reinforcing action. The fibrs are easy to handle and to disperse uniformly with in the concrete mix

EFFECTS OF SYNTHETICS FIBERS ON THE PROPERTIES OF CONCRETE:

1) FLEXURAL TOUGHNESS:
Toughness is the key propert in understanding the benefits of inclusion of fibers in concrete. Toughness is the ability of concrete to retain structural antegrity after it has nominally failed by being exposed to a load which exceeds its flexural strength. Plain, unreinforced concrete, when subjected to a bending load, will withstand that load with very little movement until the load exceeds its flexural strength. At this point, the concrete will fail suddenly and catastrophically and fall to pieces. This is the classic behavior of brittle materials possessing no toughness. That is, it has no residual strength or post cracking strength after a sudden brittle failure. But in the presence of fibers, the difference become apparent immediately after failure.at failure the concrete cracks but the crack width is initially so small that it cannot be seen. The load has been transferred to the fibers. If concrete unit continues to be loaded, then the fibers starts to pull out , and the cracks starts to widen. At this stage the unit is broken, but still able to withstand a large proportion of its maximum load. This ability to carry load after failure and to provide resistance of additional opening of the cracks in the hardened concrete is called toughness. Toughness of fibers reinforced concrete can be affected by the following factors: I. Dosage rate II. Type of fibers III. Elastic modulus IV. Fiber length V. Aspect ratio etc.

Fig 2 shows equivalent flexural strength value (ASTM C 1018) of concrete with different types of synthetics fibers. Recent study also indicates that the toughness of fiber reinforced concrete would also be affected by the strength of concrete.

FIG 2:EFFECTS OF FIBER VOLUME OF EQUAVALENT FLEXURALS TRENGHT 2) CONTROL OF SHRINKAGE CRACKS:
Shrinkage cracks are short, irregular cracks that can develop in concrete with the first 24 hrs after concrete placement. Shrinkage cracks usually pass throughthe entire depth of slab. The cracks are generally caused by either plastic or drying shrinkage. Plastic shrinkage occur before concrete reaches initial set, drying shrinkage occur after concrete set. All concrete shrinks after placement due to a volume change caused by moisture loss. If the shrinkage could take place without any restraint, the concrete would not crack. But the slab-on-grade concrete is always subjected to at least some restraint, by either the foundation, another part of the structure, or by reinforcing steel embedded in the concrete. Restraint also develops during differential shrinkage, when concrete of the surface shrinks faster than the underlying concrete, if the tensile stress caused by restraint exceeds the tensile strength of the concrete the concrete cracks. Taking precautions can minimize the possibility of shrinkage cracking. But even when you take precautions, shrinkage cracks can occur.

Synthetic fiber also control cracks the fiber in the concrete of the recommended dosages results in millions of fibers dispersed evenly throughout the concrete matrix. This multidimensional reinforcement reportedly gives fresh more tensile capacity to resist typically volume changes. It also helps distribute tensile stress more evenly. If shrinkage cracks do form, fibers bridge these cracks helping reduce their length and width. Various test, have been conducted on synthetic fiber to determine the effect of fiber on plastic shrinkage cracks. Paul kraai, a professor at san jose university (California) compared early cracking behavior of slab sample made with plan concrete , concrete reinforced with welded wire fabrics and concrete containing propylene fibers at a rate of 1 pound per cubic yard. The slabs were 2ft wide, 3ft long and 2inch thick with edge restraint by panels. Fan blew air at high velocity over the surface of the slab to force rapid drying. The result showed plastic shrinkage cracks reduction of 71.5% in the fiber reinforced sample composed with the plain concrete sample. The sample containing welded-wire fabrics showed cracks reduction of only 6.5%. 3)

DURABILITY:
Concrete products are susceptible to degradation as a result of sulphate attacks, freeze-thaw cycling, alkali silica reaction, and corrosion of embedded reinforcing bars, if present. In all of these cases permeability to water plays an important part. Durability of concrete product is therefore influenced by the rate at which water may enter. Result have indicated that permeability , in turn , depends largely on cracking in concrete, and an increase in the cracks width will produce a highly permeable concrete. Fibers reinforced improve cracking resistance increase the surface roughness of cracks and promotes multiple-crack development, thereby significantly reducing the permeability of concrete in service.

In case of stress and stress induced cracking , the permeability of plain concrete , increase dramtically while the permeability of fiber-reinforced concrete remains for below that of plain concrete under service condition. (Fig 3) Corrosion of steel reinforcing bars in concrete remains a major concern chloride contomination of concrete is usually to blame, and the mechanism by which chloride ios promotes reinforcing bar corrosion in concrete are well understod. Unfortunately cracks in concrete permits ready ingress of chloride and other deleterious chemicals and further promote corrosion , Because chloride diffusion depends principally on water permeability in both stressed and unstressed concrete and hence slow the rate of chloride diffusion. The inclusion of fiber in concrete could be a feasible solution for prolonging the life of concrete structure. A recent study has indicated that both cellulose and polyprophylene fibers might increase the co-efficient of apparent (total)

chloride diffusion but decrease the co-efficient of effective (free) chloride diffusion. In other words while greater amounts of chloride diffuse through fiber-reinforced concrete. Fiber chemically combine with the passing chloride such that only limited amount of free chloride are available for steel corrosion. This ability of fibers to bind the chlorides was further reinforced in loaded reinforced concrete beam where corrosion was delayed significantly as a result of fiber reinforcement fig 4.

FIG: 3

FIG : 4

APPLICATIONS:
Synthetic fiber reinforced concrete are used in different area of civil engineering. Synthetic fiber reinforced concrete are used in: I. II. III. IV. V. VI. VII. VIII. IX. Overlay of airfield Road pavement Industrials Bridge deck Precast concrete Canal lining Refractory lining Sewerage pipes Fabrication of precast product like pipes, boats beams, staircase steps, wall panel, roof panel, main hole etc.

REFRENCES
I. Nadeem ullah khan , Bazid khan , and Noor badshah, performance of polymeric concrete with synthetic fibers reinforcement against reflective cracking in rigid pavement overlay. Robert C.zellers, An overview of synthetic fiber reinforced concrete. M.J.Hasan , M.Afroz and H.M.I Mohmud, An experimental investigation on mechanical behavior of placro synthetic fiber reinforced concrete. Jiang jiabio, Steven Loh, Joh gosho. Synthetic structure fibers for toughness and crack control of concrete. D.Ludirdja and J.F.Young Synthetic fiber reinforcement for concrete. Cement and concrete institute Fiber reinforced concrete. Don wimpenny, peter Duxson, jony cooper, john prvis, and RoberZeuschner Fiber reinforced geopolymer concrete products for underground infrastructure. Nemkumar banthia , vivek Bindiganavile, john jones, and jeff novak Fiber reinforced concrete in precast concrete application, Research leads to innovativr products. Robert E.Xnorr and Scoff E.Nodes , P.E Polyprophylene fiber reinforce concrete detention ponds: Final report.

II. III. IV. V. VI. VII. VIII.

IX.

X. XI. XII. XIII. XIV. XV. XVI. XVII.

Michael Mahoney Structural synthetic fibers for precast and slab-on-grade construction. Anne Laning Synthetic fibers. TUF-STRAND (SF) Structural synthetic fibers for concrete reinforcement. (report) Youjiang wang, Stanley backer, vector C.Li An experimental study of synthetic fiber reinforced cementitious composite. N.Banthia Fiber reinforce concrete. Concrete technology by MS shetty. Concrete technology by AM Neville. Propreties of concrete by AM veville.