Grace Strux Beton PDF

3
Effectiveness and use of

synthetic fibres in Concrete

Gerard Attree
Engineering Services Group

Engineering Services Group EMEAI
Tuesday, 17 December
2013
2012 W. R. Grace & Co. Engineering Services Group EMEAI
History of fibres
What is STRUX?
Why STRUX?
Fibres in concrete
Performance Testing
Market Segments
Advantages with STRUX
STRUX CE Marking & Approvals
Major Projects
Replacing steel fabric with fibre reinforcement
Questions
2012 W. R. Grace & Co.
History of fibres
The use of natural fibres to strengthen brittle
materials goes back to ancient times:
3500 years ago: sun baked bricks were
reinforced with straw
In the 1950s & 1960s, steel and glass fibres
were used for concrete
Today: hundreds of different fibers are
available for use in concrete to solve different
problems
But why do we need fibres in concrete?
Why do we need fibres in concrete?
Concrete is a very brittle material
Problem concrete?
Problem concretes CRACK!
Where do we see cracks in concrete?
Fibres in concrete the options
The addition of fibres to concrete can significantly affect either the plastic and / or hardened
properties of concrete mixes

The choice of fibre to use should be made based on what properties are required from the
concrete, for example,
Reduced bleeding
Flexural toughness
Enhanced impact resistance
Freeze / thaw resistance

Adding fibres to the wrong concrete mix is not the answer!

Add fibres to a concrete mix which has been designed to accommodate fibres!
Fibre Types
Polypropylene Micro fibres
Synthetic Macro fibres
Steel fibres
Reinforcement Options

Micro
Fibres
Steel Fabric Steel
Fibres
STRUX
90/40
Safe, Easy
Handling
Plastic Shrinkage
Crack Control
Drying Shrinkage
Crack Control
Post Crack Load
Carrying Capacity
Freeze-Thaw
Protection
Non-Corroding
P
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a
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t
i
c

C
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c
r
e
t
e

H
a
r
d
e
n
e
d

C
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e

What is STRUX 90/40
Unique patented design
Excellent crack control
Excellent flexural toughness

Property Value

Specific Gravity 0.92
Tensile Strength 620 MPa
Modulus of
Elasticity
9.5 GPa
Aspect Ratio 90
Chemical
Resistance
Excellent
Absorption None
What is STRUX 90/40
Unique patented design
Excellent crack control
Excellent flexural toughness
Property Value

Specific Gravity 0.92
Tensile Strength 620 MPa
Modulus of
Elasticity
9.5 GPa
Aspect Ratio 90
Chemical
Resistance
Excellent
Absorption None
These physical properties clearly differentiates
STRUX 90/40 from its competitors other
synthetic macro fibres are much weaker in
tension (e.g. 250 MPa) than STRUX 90/40

US Patent Nos: 6.569.525; 6.569.526; 6.863.969
EP 1.253.223
Benefits of STRUX in concrete
STRUX has been designed to
provide:
Safety
Ductility
Durability
Crack control
Impact resistance
Stain free concrete surfaces
Quick, easy and safe application
Efficient and cost effective
reinforcement option
Sustainable
Three dimensional reinforcement system
Why STRUX 90/40?
STRUX fibres are completely
dispersed throughout the concrete.

Their high surface area gives them
excellent bond to the concrete matrix.
This coupled with their high strength
makes them very difficult to break or
pull out.

They work by intersecting cracks as
they begin to form. In this way,
STRUX fibres provide concrete with a
residual load carrying capacity, even
after the concrete has cracked
Testing of Synthetic Fibre Reinforced Concrete
Flexural stress vs. deflection

Grade C40 (54 N/mm
2
@ 28 days) with STRUX 90/40 @ 4.6kg/m
3

0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3
Defl ecti on (mm)
F
l
e
x
u
r
a
l

S
t
r
e
s
s

(
M
P
a
)
Beam 1
Beam 2
Beam 3
Beam 4
Peak Fl exural Strengths
Beam 1; 5.09 MPa
Beam 2; 5.72 MPa
Beam 3; 5.53 MPa
Beam 4; 6.10 Mpa
Mean; 5.61 MPa
Resi dual Fl exural Strengths
Beam 1; 2.79 MPa
Beam 2; 2.70 MPa
Beam 3; 2.52 MPa
Beam 4; 2.75 MPa
Mean; 2.69 MPa
R
e3
Val ues
Beam 1; 54.9 %
Beam 2; 47.1 %
Beam 3; 45.5 %
Beam 4; 45.1 %
Mean; 48.2 %
How does STRUX 90/40 work?
Where STRUX can be used
A wide range of internal slabs replacing fabric and light rebar
A wide range of external slabs replacing fabric and light rebar
A wide range of precast applications replacing fabric and light rebar
Steps
Parking
kerbs
Septic
tanks
Manholes
Pipes
Insulated wall
panels
Sea Defence
Segmental Linings
Sprayed concrete applications replacing fabric, steel fibres and
light rebar
Composite metal decking applications replacing fabric
Advantages of STRUX 90/40
Speed of use
Reinforcement is delivered and poured with the concrete.
STRUX 90/40 is distributed uniformly throughout the concrete.
Health & Safety
No exposed steel or onsite storage.
High fibre content at low dosage weight.
Exposed fibres
Surface, STRUX 90/40 fibres pose no corrosion or durability problems.
Improved flexural toughness
Especially in elements of 4 (100 mm) and more.
Enhanced impact resistance.
Plastic shrinkage control.
No need for additional plastic shrinkage fibres.
Low environmental impact
Viable option for production of low carbon concrete.
STRUX macro-fibres can achieve the same performance as steel
fabric with several benefits
Traditional Reinforcement Challenges
Traditional industry practice uses steel fabric for crack control
Challenges of using steel fabric
Difficult to pour and consolidate
concrete with steel fabric.
Represents an additional step in
the construction; placing requires
Health & Safety considerations.
Effectiveness of crack control
depends on position of the fabric.
Corrosion and Durability problems
associated with cracking and mesh
position
Hauling & stocking is not always
easy and can be expensive.
CE marking, EN14889-2
CPD
Construction
Products
Directive
CPR
Construction
Products
Regulations
J uly 1
st
2013

CE marking
required for
legal sale
Voluntary
Declaration of Product
Performance based on:
Harmonised technical
specification
Agreed system of conformity
assessment
Framework of Notified Bodies
CE Marking of products
CE Marking indicates a product is
consistent with its Declaration of
Performance
In the case of macro-synthetic fibres like
STRUX a declared value according to EN
14889-2 is used
The declared values include tensile strength
and elastic modulus and a dosage to
achieve a standard performance
Performance equals dosage efficiency
There are further requirements within the
test that must be observed
Constant, single length fibres
Fibre must be tested as sold
Polymer fibres for concrete
Polymer type: Polypropylene/Polyethylene
Class II
Length: 40mm
Equivalent Diameter: 0.433 mm
Shape: cross sectional area rectangular
Tensile strength: 620N/mm
2
Elastic modulus: 9500 N/mm
2

Effect on consistence with 3.5kg/m
3
fibres:
Vebe time: 10s (Reference concrete 7s)

Effect on strength of concrete:
3.5kg/m
3
to obtain 1.5N/mm
2
at CMOD=0.5mm
and 1 N/mm2 at CMOD=3.5mm
UK
High
tensile
strength
indicates a
stronger
fibre
Indicates
residual
(post-crack
flexural
strength)
performance
BS EN 14889-2
Confidence in Quality, Performance and Pedigree
External approvals
Confidence in Quality, Performance and Pedigree
Khalifa Port and Industrial Zone Project
STRUX Project Profile

Product: STRUX 90/40
Project Name: Khalifa Port and
Industrial Zone Project Container
Terminal
Location: Taweelah Abu Dhabi
Total Project value: $390 Million
Total Project Area: 1,000,000m
2
Project Start and finish: Mar 2011
Feb 2012
100 year service life guarantee
required for slab in high chloride
conditions required both high
durability concrete and a non
corroding reinforcement no
practical alternative to macro
synthetic fibers.
STRUX chosen due to previous
pedigree and specifier familiarity.

West Metro Shotcrete Tunnel Lining - Finland
STRUX Applications

Dosage: 7kg/m
3
Contractor: Lmminkeinen
Readymix: Rudus
STRUX 85/50 best performing fibre
of those tested for energy
absorption and rebound.
Faster completion compared to
steel fibres as no protective
coating for pipes and services
needed
Use of STRUX fibre dispenser with
bulk (70kg) bags

The Georgia Aquarium, Atlanta, USA

Designed to look like a modern
Noahs Ark, the new Georgia
Aquarium in downtown Atlanta
destined to be the largest
aquarium in the world and one of
the major tourist attractions in the
state.
Given the challenging nature of the
project a team from Grace
Construction Products had to meet
the complex demands of this
construction. The tanks are among
the largest in the world.
STRUX 90/40 was used for
secondary reinforcement in slab
on- ground concrete throughout
the structure, including concrete
walkways, areas near the tanks
and other high traffic locations.
STRUX is safer to use, reduces
the potential for damage to
waterproofing materials placed
under the concrete and eliminates
the risk for corrosion compared to
other types of reinforcement.
New Sea Defence, Blackpool, UK
76m scheme to future proof the
north wests leading holiday resort
against flooding.
Blackpool Central Area Coast
Protection Scheme employed
innovative design and construction
techniques to deliver a flagship
scheme combining vital coastal
protection improvements along
with an enhanced seafront
environment.
Enhanced durability of the
revetment was achieved using
STRUX 90/40 reinforcement in
place of steel reinforcement.
Similarly, use of novel polymer
reinforcement in the precast
elements offered major
construction enhancements. This
was the first time these materials
had been used on this scale in the
UK.
It won the North West Civil
Engineering Large Project of the
Year for 2011

Bridges Wharf Car Park, London, UK
Product: STRUX 90/40 & ADVA
Floor 250
Application: Concrete Topping
Engineer: Waterman Group
Main Contractor: Westcrete
Specialist Floor Layer: Technic
The Engineers brief was to
provide a solution to reduce the
risk of corrosion that could become
an issue if traditional steel fabric
was used in the concrete for the
car park areas within this private
development and reduce the
amount of joints.
Grace worked closely with all
parties on the project to assist with
providing a detailed design solution
while also working with the
contracts team to assist with mix
design and placement advice.
ADVA Floor 250 & STRUX 90/40
placed on top of the Hydroduct
CF20 was a major benefit to the
Engineer in reducing any exposure
to remedial or repair costs.

Summary:
STRUX synthetic macro fibres provide:
Comparable crack control to steel fabric and steel fibres
No corrosion issues
Reinforcement is delivered and poured with concrete always in the right place
3 dimensional reinforcement
Reduced project costs
Reduced project times
Safer construction environment
Pedigree
Credibility

Durability Products Contacts EMEAI Region
Contact Name Gerard Attree
Contact Title Engineering Services Group Manager
Contact Phone Number +44 (0) 7808 635229
Contact Email Address Gerry.Attree@grace.com
Thank you for your attention, any questions?

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Effectiveness and use of

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