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.



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



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



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



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



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



< 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



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



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



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



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



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 &.)&



<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



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



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" .

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ompressive +trength /odulus of 4upture +plit ensile +trengh

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*.& 0).* 3&.) ).5& ).0% %.1% %.1&Properties and <pplications of

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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



< 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



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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F. 5. -ffect of hoo#ed fiber contenl on fle$ural .'trength at

=1il#rJAnl aLLJA,.(& Faisal Fouad :afa

+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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at different ages.

oughness !-nergy <bsorption"



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



&.& 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.

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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



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)".



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".



!? :illiamson, .4., 4esponse of Fibrous'4einforced oncrete to

-$plosive =ading, C.+. <rmy -ngineer. 9ivision, echnical 4eport

Go.

Properties of polymer concrete

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