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ULTRA-NET
SUPER-NET
ECONO-NET
ECONO-NET
Overview
FAQ's
Projects
APPLICATIONS
FORTA ECONO-NET is mainly used in concrete applications such as slab-on-grade,
overlays/toppings, curbs, slope paving, driveways, sidewalks, basement floors, garage floors,
architectural/colored concrete, precast, mortar, grout, water tanks, and sewage treatment
facilities anywhere that superior fiber performance is desired and where the objective is to
INSTALLATION
Recommended dosage rate of FORTA ECONO-NET is 1.5 lbs. per cubic yard (0.9 kg. per
cubic meter) of concrete added directly to the concrete mixing system during, or after, the
batching of the other ingredients and mixed at the time and speed recommended by the mixer
manufacturer (usually four to five minutes).
PHYSICAL PROPERTIES
Materials: Virgin Homopolymer Polypropylene
Form: Collated Fibrillated Fiber
Specific Gravity: 0.91
Tensile Strength: 83-96 ksi. (570-660 MPa)
Length: 3/4" (19mm), 1-1/2" (38mm)
Color: White
Acid/Alkali Resistance: Excellent
Absorption: Nil
Compliance: A.S.T.M. C-1116
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Panels
composites
including
concretes
are
the
main
ceramic-based
materials. Concrete offers many advantages in the application due to its improved
mechanical characteristics, low permeability and higher resistance against chemical
and mechanical attacks. Although concrete behavior is governed significantly by its
compressive strength, the tensile strength is important with respect to the
appearance and durability of concrete. The tensile strength of concrete is relatively
much lower. Therefore, fibers are generally introduced to enhance its flexural tensile
strength, crack arresting system and post cracking ductile behaviour of basic
matrix.
Concrete modification by using polymeric materials has been studied for the past
four decades [3]. In general, the reinforcement of brittle building materials with
fibers has been known from ancient period such as putting straw into the mud for
housing walls or reinforcing mortar using animal hair etc. Many materials like jute,
bamboo, coconut, rice husk, cane bagasse, and sawdust as well as synthetic
materials such as polyvinyl alcohol, polypropylene (PP), polyethylene, polyamides
etc. have also been used for reinforcing the concrete [4,5,6,7,8]. Research and
development into new fiber reinforced concrete is going on today as well.
Polypropylene fibers were first suggested as an admixture to concrete in 1965 for
the construction of blast resistant buildings for the US Corps of Engineers. The fiber
has subsequently been improved further and at present it is used either as short
discontinuous fibrillated material for production of fiber reinforced concrete or a
continuous mat for production of thin sheet components. Since then the use of
these fibers has increased tremendously in construction of structures because
addition of fibers in concrete improves the toughness, flexural strength, tensile
strength and impact strength as well as failure mode of concrete. Polypropylene
twine is cheap, abundantly available, and like all manmade fibers of a consistent
quality.
Properties of Polypropylene Fibers
The raw material of polypropylene is derived from monomeric C3H6 which is purely
hydrocarbon. Its mode of polymerization, its high molecular weight and the way it
is processed into fibers combine to give polypropylene fibers very useful properties
as explained below [9]:
crystallinity.
Due
to
regular
structure,
it
is
known
as
isotactic
polypropylene.
The hydrophobic surface not being wet by cement paste helps to prevent
chopped fibers from balling effect during mixing like other fibers.
The orientation leaves the film weak in the lateral direction which facilitates
fibrillations. The cement matrix can therefore penetrate in the mesh structure
between the individual fibrils and create a mechanical bond between matrix and
fiber.
Figure 1: monofilament
Figure 2: Fibrillated
fiber
fiber
The fibers are manufactured either by the pulling wire procedure with circular cross
section or by extruding the plastic film with rectangular cross-section. They appear
either as fibrillated bundles, mono filament or microfilaments as shown in Fig. 1 &
2. The properties of these three types of PP fibers are given in Table 1 [10]. The
fibrillated polypropylene fibers are formed by expansion of a plastic film, which is
separated into strips and then slit. The fiber bundles are cut into specified lengths
and fibrillated. In monofilament fibers, the addition of buttons at the ends of the
fiber increases the pull out load. Further, the maximum load and stress transfer
could also be achieved by twisting fibers [11].
Role of Fibers
Cracks play an important role as they change concrete structures into permeable
elements and consequently with a high risk of corrosion. Cracks not only reduce the
quality of concrete and make it aesthetically unacceptable but also make structures
out of service. If these cracks do not exceed a certain width, they are neither
harmful to a structure nor to its serviceability. Therefore, it is important to reduce
the crack width and this can be achieved by adding polypropylene fibers to concrete
[13]. The bridging of cracks by the addition of PP fibers has been shown in Fig 3.
Thus addition of fibers in cement concrete matrix bridges these cracks and restrains
them from further opening. In order to achieve more deflection in the beam,
additional forces and energies are required to pull out or fracture the fibres. This
process, apart from preserving the integrity of concrete, improves the load-carrying
capacity of structural member beyond cracking. This improvement creates a long
post-peak descending portion in the load deflection curve as shown in Fig 4 [12].
Reinforcing steel bars in concrete have the same beneficial effect because they act
as long continuous fibres. Short discontinuous fibres have the advantage, however,
of
being
uniformly
mixed
and
dispersed
throughout
the
concrete.
The major reasons for crack formation are Plastic shrinkage, Plastic settlement,
Freeze
thaw
damage,
Fire
damage
etc.
Plastic shrinkage: It occurs when surface water evaporates before the bleed
water reaches the surface. Polypropylene fibers reduce the plastic shrinkage crack
area due to their flexibility and ability to conform to form. The addition of 0.1% by
volume of fibers is found effective in reducing the extent of cracking by a factor of
5-10. The extent of crack reduction is proportional to the fiber content in the
concrete.
Table 1: Properties of various types of polypropylene fibers
Fiber type
monofilamen
t
microfilamen
t
Fibrillated
Length Diameter
Tensile
Modulus of
Specific
strength
elasticity
surface
(MPa)
(GPa)
(m2/kg)
Density
(mm)
(mm)
(kg/cm3)
30-50
0.30-0.35
547-658
3.50-7.50
91
0.9
12-20
0.05-0.20
330-414
3.70-5.50
225
0.91
19-40
0.20-0.30
500-750
5.00-10.00
58
0.95
Plastic settlement: High rate of bleeding and settlement combined with restraint
to settlement (e.g. by reinforcing bars) leads to settlement cracking. In case of
PFRC, fibers are uniformly distributed. Fibers are flexible so they cause negligible
restraint
to
settlement
of
aggregates.
capillary pores
of PP fibers
Figure 5: Flowing out of steam pressure through the melted PP fibers in the case of fire
Before mixing the concrete, the fiber length, amount and design mix variables are
adjusted to prevent the fibers from balling. Good FRC mixes usually contain a high
mortar volume as compared to conventional concrete mixes. The aspect ratio for
the fibers are usually restricted between 100 and 200 since fibers which are too
long tend to "ball" in the mix and create workability problems. As a rule, fibers are
generally randomly distributed in the concrete; however, placing of concrete should
be in such a manner that the fibers become aligned in the direction of applied
stress which will result in even greater tensile and flexural strengths. There should
be sufficient compaction so that the fresh concrete flows satisfactorily and the PP
fibers are uniformly dispersed in the mixture. The fibers should not float to the
surface nor sink to the bottom in the fresh concrete. Chemical admixtures are
added to fiber-reinforced concrete mixes primarily to increase the workability of the
mix. Air-entraining agents and water-reducing admixtu- res are usually added to
mixes with a fine aggregate content of 50% or more. Superplasticizers, when added
to fiber-reinforced concrete, can lower water: cement ratios, and improve the
strength, volumetric stability and handling characteristics of the wet mix. The
properties of PFRC with various fiber volume % are shown in Table 2.
Table 2 Mechanical Properties of Polypropylene Fiber Reinforced Concrete
Concrete mix
Vf
Fibers
N
o
w/
c
1.
Cement
)
390
(OPC)
FA
Specim
0.4
2. 0.4
CA
3)
3)
(10mm
640
plasticizer
(Fosroc
430)
647
Type
shape
Super
1000
en
Cylinder
, Cubes
& Prism
Prism
& 0.29mm
1100
Micro
(OPC)
(20mm
filament
fs
a)
a)
Slu
mp Re
(mm f.
)
d
0
0.1 17.2 1.08 4.5
69
dia)
360
ft
l/
Fibrillated
(20mm long
fcu
100
120
[1
5]
0
39
--
2.24 4.01
--
[1
6 0.0
2.33 3.76
0]
(19mm long
45
2.40 4.01
& 0.048mm
0.0
dia)
82
0.1
2.43 4.22
28
Mono
3.
0.4
360
(OPC)
1100
(20mm
filament
647
Prism
1.0
1.4
--
2.50 5.36
2.68 5.47
2.70 5.51
[1
0]
dia)
35.0
4.
0.4
418
(OPC)
724
(25mm
998
Cylinder
Mono
filament
0
56 1.0
1.5
3
35.4
2
30.7
2.23
3.21 - - 3.21
102
38
7
[1
6]
5.
+ 28 SF
56.1
1140
(20mm
750
Superplasticizer
Prism
Mono
filament
20
4.10 5.21
100
[2
80
9]
0
35.2
3
6.
0.5
383
(PPC)
1162
(20mm
Cylinder
572
, Cubes
& Prism
Graded
Fibrillated
N 0.1
(12mm ~
24mm)
0.3
0
0
4.42 5.47
4.95 6.35
--
[2
5]
48.0
0
41.2
2
7.
0.4
430
(PPC)
1154
(20mm
Cylinder
540
, Cubes
& Prism
Graded
Fibrillated
N 0.1
12mm ~
24mm)
0.3
8
2
4.53 5.99
4.75 6.29
--
[2
5]
52.0
0
8. 0.3
9
498
1136
(PPC)
503
NIL
Cylinder
Graded
(20mm
, Cubes
Fibrillated
& Prism
12mm ~
24mm)
--
[2
4.88 5.70
5]
R 0.1
0.3
5.52
55.3
3
6.84
57.1
1
Superplastic
9.
0.3
567
(OPC)
630
1050
izer
(Paric
Fibrillated
Cylinder
FP300U)
0. 0
567
(OPC)
630
1050
izer
(Paric
1 0.3
1. 6
1 0.4
2. 0
1268
713
Super
plasticizer
(20mm
Cylinder
mm long&
0.06mm di)
Cylinder
, Cubes
& Prism
Mono
filament
Mesh Type
0.2
5
0.5
0
740
Cubes &
Cylinder
Fibrillated
81.6
0
60.8
0
60.0
4.40
4.10
4.30
--
400- [2
600
3]
0.2 71.9
50
5.40
70 0.1
0
15 0.1
0
0
0
1120
415
& 0.06 mm
Fibrillated(30
FP300U)
314OPC
(6 mm long 10
dia)
Superplastic
1 0.3
--
400- [2
600
3]
0
38.2
0
37.6
0
37.2
4.80
73
5.10
55
5.40
45
[3
0]
0
38.0 4.00
--
20
20
[2
15
8]
10
Where: Vf - volume fraction of fiber; f cu - compressive strength; ft - tensile strength and f s - flexural
strength, SF- Silica fume
Effects
on
Fresh
Concrete
The main parameter, which is often used to determine the workability of fresh
concrete, is the slump test. The slump value depends mainly on the water
absorption and porosity of the aggregates, water content in the mixture, amount of
the aggregate and fine material in the mixture, shape of the aggregates and
surface characteristics of the constituents in the mixture. The slump values
decrease significantly with the addition of polypropylene fibers as shown in Table 3.
The concrete mixture becomes rather clingy resulting in increasing of the adhesion
and cohesiveness of fresh concrete. During mixing the movement of aggregates
shears the fibrillated fibers apart, so that they open into a network of linked fiber
filaments and individual fibers. These fibers anchor mechanically to the cement
paste because of their large specific surface area. The concrete mixture with
polypropylene fibers results in the fewer rate of bleeding and segregation as
compared to plain concrete. This is because the fibers hold the concrete together
and thus slow down the settlement of aggregates. Due to its high tensile and pullout strength, the PP fibers even reduce the early plastic shrinkage cracking by
enhancing the tensile capacity of fresh concrete to resist the tensile stresses caused
by the typical volume changes. The fibers also distribute these tensile stresses
more evenly throughout the concrete. As the plastic shrinkage cracking decreases,
the number of cracks in the concrete under loading is reduced, due to decrease in
cracks from the existing shrinkage cracks. If shrinkage cracks are still formed, the
fibers bridge these cracks, reducing at the same time their length and width.
Moreover, as the rate of bleeding decreases, the use of polypropylene fibers may
accelerate the time to initial and final set of the concrete as this led to a slower rate
of drying in the concrete [14].
Table 3: Effect of polypropylene fibers on concrete slump [18]
(mm)
Effects
Initial slump
Final slump
Fiber length
(mm)
(mm)
(mm)
90
76
51
130
70
51
170
120
30
127
48
51
1245
53
51
114
64
19
on
Hardened
Concrete
The addition of polypropylene fibres in the concrete did not significantly affect the
compressive strength and the modulus of elasticity but they do increase the tensile
strength. Splitting tensile strength of PFRC approx ranges from 9% to 13% of its
compressive strength. Addition of PP fibers in concrete increases the splitting
tensile
strength
by
approx
20%
to
50%
[16].
of PFR concrete
Bond strength: It is necessary that there should be a good bond between the fiber
and the matrix. If the critical fiber volume for strengthening has been reached then
it is possible to achieve multiple cracking. This is a desirable situation because it
changes a basically brittle material with a single fracture surface to fracture into a
pseudo ductile material which can absorb transient minor overload and shocks with
little visible damage. So the aim is to produce large number of multiple cracks at as
close spacing as possible so that the crack widths are very small, almost invisible to
naked eye so that the rate at which aggressive materials can penetrate the matrix
is reduced. High bond strength helps to give close crack spacing but it is also
essential that the fibers should give sufficient ductility to absorb impacts. But in
terms of physiochemical adhesion there is no bond between the fiber and the
cement gel. The use of chopped and twisted fibrillated polypropylene fibers with
their open structure has partially remedied the lack of interfacial adhesion by
making use of wedge action at the slightly open fiber ends and also by mechanical
bonding through fibrillation. The general pull out loads of twisted fibrillated fibers
[20, 21] may range from 300-500N for commonly used staples but the accurate
calculation of bond strength is complicated by a lack of knowledge of the surface
area of fiber in contact with the paste. It is observed that in damaged products and
in broken specimens, usually fiber breaks instead of fiber pull out [9].
Fracture
Properties:
The
failure
behaviour
of
high-strength
concretes
is
effectively improved by the use of fibers. The typical shear bond rupture due to
strain localization could be avoided (fig. 6). Instead of this, a large number of the
longitudinal cracking, which was predominantly oriented in the direction parallel or
sub-parallel to the external compressive stresses, was formed at the entire concrete
specimens
as
shown
in
fig7.
Creep and shrinkage properties of concrete: Fibers reduce creep strain, which is
defined as the time-dependent deformation of concrete under a constant stress.
Compressive creep values, however, may be only 10 to 20% of those for normal
concrete. Shrinkage of concrete, which is caused by the withdrawal of water from
concrete during drying, is also reduced by fibers. The shrinkage, creep and total
time dependent deformation of various PFRC mixes along with non fibrous concrete
mix are presented in fig 8[15]. The reduction in shrinkage due to the presence of
fibers is expected from number of viewpoints. First, the fibers do not exhibit any
shrinkage, thus reducing overall shrinkage of the mix. In addition the fibers have a
role in retaining the water in the concrete mix upto a certain limit which helps to
delay the shrinkage. Therefore addition of fibers to the concrete mixes is always
advantageous in reducing shrinkage deformation.
polypropylene fibers
of concrete
Flexural impact properties: The number of blows required to develop the first
visible crack on the beams lower surface is defined as the initial-crack impact
number (Ncr). Failure impact number Nf is defined as the number at which one main
macro-crack develops from bottom to top of the beam. Impact ductility index is
defined as the ratio of failure impact number to initial crack impact number, which
can
be
used
to
present
J=Nf
the
flexural
impact
ductility.
Ncr
where J is impact ductility index, which for plain concrete is 1. The flexural impact
test results are shown in table 6 by researcher[10]. The impact resistance for
concretes with various volume fractions of fibrillated polypropylene fibers has been
shown in figure 10. The results indicate that significant improvement in impact
resistance of concrete can be achieved with relatively low volume fraction of
polypropylene fibers.
Table 6: Impact properties of fiber reinforced concrete
Type of mix Vf % Average Impact number
Control
0
0.05
Microfilament
0.09
5
0.14
Average failure
Impact number
25.8
26.8
1.04
34.7
46.5
1.34
28.6
30.4
1.06
38.1
40.1
1.05
68.9
224.2
3.26
Monofilament 1.2
70.7
712.7
10.08
1.4
62.8
831
13.23
been
used
for
controlling
shrinkage
&
temperature
cracking.
easy to place, compact, finish, pump and it reduces the rebound effect in sprayed
concrete applications by increasing cohesiveness of wet concrete. Being wholly
synthetic there is no corrosion risk. PFRC shows improved impact resistance as
compared to conventionally reinforced brittle concrete. The use of PFRC provides a
safer working environment and improves abrasion resistance in concrete floors by
controlling the bleeding while the concrete is in plastic stage. The possibility of
increased tensile strength and impact resistance offers potential reductions in the
weight and thickness of structural components and should also reduce the damage
resulting
from
shipping
and
handling.
Acknowledgment
The author wishes to express his sincere thanks to Ms Sonal Dhanvijay & Ms
Vedanti Ganwir of Visvesvaraya National Institute of Technology, Nagpur for their
valuable help in preparing this paper.