MFG

An ISO 9001:2008 company

Kasturi Metal Composites - Introduction

Visit us @ www.steelfiberindia.in ; www.metalcomposites.comBlog : www.fiberconcrete.in

Agenda

Welcome - Kasturi Metal Composites

Company Introduction Product Portfolio – Types of Concrete Fibers Fiber Reinforced Concrete –

Concept Introduction and Advantages Applications Design Considerations

Product Test Certificates Our Services Our Clients

An ISO 9001:2008 company

Kasturi Metal Composites - Introduction

Head Office

3 separate plants for fiber production

Kasturi Metal Composites - Introduction

Founded in 1999 and incoporated as Pvt Ltd in 2004

Founder - Mr Samit Singhai. (MS -Industrial Engineering, USA)

“Best Industry Award” from Govt of Maharashtra (Twice)

Only Indian company to manufacture

Glued Hook End Steel Fiber

Macro Synthetic Polypropylene Fiber

Unique Services for Flooring Applicators/Contractors

Complete Customized Design Solution – As per Site

Cost Comparison for SFRC Industrial Flooring

Types of Fibers Used Structural Fibers

Steel Fibers: These fibers are generally used for providing concrete with enhanced toughness and post-crack load carrying capacity. Dia varying from 0.5 mm to 1 mm and length from 25 mm to 60 mm Tensile Strength from 500 Mpa to 2500 Mpa Dosage varying from 12 kg cum to 50 kg cum.

Macro-synthetic fibers: This newer class of fibers has emerged over the past 15 years as a suitable alternate to steel fibers when dosed properly. Typical materials include polypropylene Dia Varying from 0.6 mm to 1mm and length from 35 mm to 65 mm Tensile Strength varies from 320 Mpa to 650 Mpa. Dosage varying from 1 kg cum to 7 kg cum.

Non- Structural Fibers Micro-synthetic fibers: These fibers are generally used for the protection and mitigation of

plastic shrinkage cracking in concrete. Most fiber types are manufactured from polypropylene, polyethylene, polyester, nylon etc Length varying from 5 mm to 25 mm Tensile Strength varies from 320 Mpa to 450 Mpa. Dosage varying from 100 gms cum to 1 kg cum

Product Portfolio – Polypropylene FibersAs per ASTM C1116

Micro Monofilament PP Fibers Micro Fibrillated PP Fibers

• Level 1 - reinforcement

• Non – Structural Fibers

DurocreteTM Micro PP Fibers

Product Portfolio – Steel FibersAs per ASTM A820 M04 Standards

Glued Hook End Steel Fibers Loose Hook End Steel Fibers

Flat End Steel Fibers

• Level 2 - reinforcement

• Structural Fibers – Steel

Product Portfolio

Macro Synthetic PP Fibers

• Level 3 - reinforcement

• Structural Fibers – Macro Synthetic and Steel Blend

Hook End Steel Fibers

Fiber Reinforced Concrete – Introduction Why does Concrete needs Reinforcement ? Fiber Reinforced Concrete Benefits of Fiber Reinforced Concrete Application of FRC DURAFLEX – as an advantage

Concrete Reinforcement

Why does concrete needs reinforcement ? Concrete is brittle in nature and tends to

shrink slightly both during and after curing Thermal Contraction and expansion due to

temperature and moisture changes. Plastic shrinkage occurs at the surface and

volumetric changes cause internal stresses within the concrete matrix

To provide additional tensile strength to the internal structure - Rebar and Welded Wire Mesh are used (Conventional Reinforcement)

IS THIS METHOD OF PRIMARY REINFORCEMENT ADEQUATE ????

Cracks Formation

Chips Formation

Major Issues with Industrial Flooring due to Internal Stresses

Solution : Fiber Reinforced Concrete

Turns Brittle material into ductile

Intercepts micro-cracks as they form and continue to provide tensile capacity across the cracks.

THE FIBRE ADVANTAGE

Continue to bridge crack, pulling concrete on either side of crack

FRC clearly affects the post cracking behavior of reinforced concrete – MORE TOUGHER MORE IMACT RESITANCE MORE LOAD CARRYING CAPACITY

Offer

High-Tech Protection

against

CRACKING ! CRACKING !

STEEL FIBRESSTEEL FIBRES

Conventional Reinforcement

Provides single point crack restraint only

Control micro-cracking in hardened Concrete

Steel fiber reinforced concrete

Steel fiber reinforced concrete

• Provide continuous crack restraint– From bottom of slab to just below surface

SETTLEMENT

Plain ConcretePlain ConcreteVARIABLE BLEEDING & SUPPORT

Steel Fiber ConcreteSteel Fiber Concrete

STEEL FIBER REDUCES BLEEDING & SETTLEMENT RESULTING IN A MORE HOMOGENIOUS MIX

VV Rebar / Wire MeshRebar / Wire Mesh• 3 Dimensional Reinforcement

• Always placed correctly

• Reinforces against shrinkage cracking.

• Reduces Bleeding & Settlement.

• Improves Impact & Abrasion Resistance.

• Provides Shatter & Spalling Resistance.

• Reduces Permeability

• Improves Freeze/Thaw Resistance.

• Provides Resistance to Explosive Spalling.

• Induced Joints recommended at 6m centres.

• 2 Dimensional Reinforcement

• Difficult to place correctly

• Controls Cracks once they have occurred

• Induced Joints recommended at 10m centres.

STEELSTEEL FIBRESFIBRES

SFRC Properties

COMPRESSION

FLEXURE SHEAR

Compression

Compressive Strength Equals 28 MPa

Compressive Strength is Marginally Enhanced

Compressive Strain Behavior IS Enhanced

SFRC Properties

Load Vs Deflection : Toughness Test

SFRC Properties

ASTM C 78

Flexural Strength Equals 5.2 MPa

Flexural Strain Capacity IS Enhanced

Impact

SFRC Properties

Impact Resitance

Plain 0.5 0.1 1.5 2

Dosage Percentage

Num

ber o

f Blo

ws

to fa

ilure

SFRC Properties

SFRC Vs Normal Concrete

 MIX DESIGN FOR S.F.R.C.

Cement Content 300 - 500 Kg/m3

Water cement ratio 0.45 to 0.60

Ratio of sand to total aggregates as percent

50 to 100

Max. size of aggregate 10 to 20 mm

Fiber aspect ratio 50 to 100.

Fiber content 15 kg to 30 Kg/m3

Sample MIX

Major Application – Industrial Flooring

Flooring applications include

Industrial Floors Warehouse and Cold Storage Floors

Ports and Dockyards Airport Runways

Residential township Internal Roads Cement Factories

Roads and Pavements Workshops and Garages

To the Contractor Reduced labor cost Decreased Schedule Time

Steel fibres installed in 5 minutes vs long hours taken by wire mesh

Truck can be driven up to forms and may eliminate the need for pumps

Faster construction Easy to handle Environmentally friendly packing Supports Laser Screeds, Vibratory Screeds

and compatible with all types of conventional tremix equipments.

Benefits of SFRC Floors

To the Owner Low cost of construction High quality - Eliminates concern that mesh is not in the

right place - Stops micro cracks propogating into macro

cracks - Reinforces the edge helping to prevent

joint failure - Provides high impact resistance - Excellent surface finish can be achieved - Eliminates spalling due to corroding

reinforcement

Benefits of SFRC Floors

Benefits of SFRC Floors

To the Consultant

Design validated by performance tests. Proven performance in the field. Fully detailed design guide as per standard codes. Full support for Site mixing, Laying and Finishing.

Renowned Name – Largest Manufacturer in India

Lead Sharing – Working Together Complete Design Assistance Cost Comparison with Best Economical

Design as per the site requirement On Site Assistance Trading Opportunities – Channel Partner www.fiberconcrete.in – knowledge sharing

platform(bringing experts and research together)

Advantage Kasturi

Duraflex™ Steel Fibers- Advantage

Stringent Quality Control Processes : QMS Tensile Strength always maintained above 1100 Mpa.

(Regular available in market around 800-1000 Mpa) Correct Anchorage and Aspect Ratio (L/D) maintained. Packaged in a special waterproof Packaging bag

Test Certificates – Flexural StrengthTested at IIT-Roorkee Dep of Earthquake Eng

Our Services

On Site technical Assistance

Customized Design Solutions along with Cost Comparison

Wide Applicator Network

Fiber for varied application – Largest Producer

Few of Our Esteemed Corporate Clients

And many more……….

Thank you !

We appreciate your attention.