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To:Foundation Performance Association
Fiber Reinforced ConcreteFiber Reinforced Concrete
By: Patrick Greer
Fibermesh – Novomesh - NovoconFibermesh – Novomesh - Novocon
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Global Footprint
Headquarters
Manufacturing Facilities
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1 Company . . . 4 Business Units
Geosynthetics Performance
Technologies
Concrete
Solutions
Furnishing
Solutions
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Concrete SolutionsMaking Good Concrete Better®
Markets
• Residential & Commercial
Slabs-On-Ground
• Composite Metal Decks
• Industrial Flooring
Brands
• ENDURO®
• Fibermesh®
• Fibercast®
• Novomesh®
• Transportation
• Walls
• Precast Concrete
• Shotcrete & Underground
•• Novocon®
• Fibreflor®
• SigmaJoint®
• Elemix®
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FRC - Seminar
OutlineI. Micro Fiber applications in Concrete
II. Slab & Pavement: On Grade Construction• Traditional Reinforcement Design
• FRC in ACI 360
II. FRC Solutions - Steel & Macro Fiber ApplicationsII. FRC Solutions - Steel & Macro Fiber Applications• Design Criteria
• Steel fibers
• Blended Solutions
• Macro-Synthetic Fibers
• Composite Metal Decking
I. Texas DOT Fiber Acceptance Criteria• Testing Criteria
• Dosage Rates and Applications
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Mo
no
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Fib
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Engineered BlendsMacro-synthetic
and Steel
Ma
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Fiber Reinforced Concrete Fiber Reinforced Concrete SolutionsSolutions
Mo
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fila
me
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Fib
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Ste
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Early Age Performance
Long-term Performance
Crack Prevention Crack Containment
Ma
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The Correct Fiber Fit for your Project
• Any Cast in Place Concrete
• Microsynthetic Fibers : Monofilament or Fibrillated
• Slabs & Pavement: w/ Close Joint Spacing using Light Gage WWF
• Microsynthetic: Fibrillated
• Slabs & Pavements: Using Heavy WWF or Light Duty Rebar (> w2.9)
• Macrosynthetic – Steel – Engineered Blends• Macrosynthetic – Steel – Engineered Blends
• Composite Metal Decking
• Macrosynthetic – Steel – Engineered Blends
• Heavy Commercial - Industrial Slabs & Pavements
• Steel Fibers – Engineered Blends
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Monofilament- Multifilament. Plastic
concrete crack reduction. Excellent
finishability.
Fibrillated - Fibrillated. Plastic concrete
Family of Micro-Synthetic Polypropylene Fibers
Fibrillated - Fibrillated. Plastic concrete
crack reduction, moderate toughness.
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Multifilament
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Residential Slabs-On-Grade
Thousands of SuccessfulResidential ApplicationsWorldwide Since 1982
Monofilament FibersInhibit Plastic Shrinkage andSettlement Cracking
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2 – 4’’ of high strength fiber
reinforced
concrete is placed over
prepared,
distressed asphalt.
FRC = 80 PSI - ARS
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Gonzales to Sealy, TXGonzales to Sealy, TX
Fibermesh 300 @ 3 lbs. per cubic yard
ARS – 81 psi
Fibermesh 300 @ 3 lbs. per cubic yard
ARS – 81 psi
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I-10 Mow Strip (length-80 miles)I-10 Mow Strip (length-80 miles)
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Microsynthetic FIBERS• Inhibit Early Age Shrinkage Cracking
• Reduce Settlement Cracking
• Increases Impact Resistance
• Increases Shatter Resistance
• Reduces Water Migration
• Increases Abrasion Resistance
• Reduces Rate of Corrosion• Reduces Rate of Corrosion
• Increases Rebar Bond to Concrete
• Measurable Residual Strength
• Alternate System to Welded Wire Fabric (Slabs)
•• AntiAnti--SpallingSpalling
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APPLICATIONS of MICRO-SYNTHETIC FIBERS for RESISTANCE to EXPLOSIVE SPALLING in FIRES
APPLICATIONS of MICRO-SYNTHETIC FIBERS for RESISTANCE to EXPLOSIVE SPALLING in FIRES
NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006
Trevor Atkinson Peter Tatnall
Director of Underground Concrete Principal
SI Concrete Systems Performance Concrete Technologies
NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006NAT 2006Chicago, IllinoisChicago, IllinoisChicago, IllinoisChicago, IllinoisChicago, IllinoisChicago, IllinoisChicago, IllinoisChicago, Illinois
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• Great Belt Tunnel (Denmark, 1994)
• Channel Tunnel (UK-France, 1996)
• Mont Blanc (Italy-France, 1999)
Tunnel Fires
1999)• Tauern (Austria, 1999) • Kaprun (Austria, 2000) • Gotthard
(Italy-Switzerland, 2001)• Baltimore Rail Tunnel (2002)
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Explosive Spalling
• Most DANGEROUS form of spalling
• Occurs during first 20 – 30 minutes when rapid • Occurs during first 20 – 30 minutes when rapid
heat rise is encountered.
• Characterised by forcible separation of pieces of
concrete and accompanied by a loud bang.
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Non-Fibrous Concrete
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Non-Fibrous Concrete
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Polypropylene Fiber Reinforced Concrete
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Polypropylene Fibre Reinforced Concrete
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CTRL Tests
Intermediate Test Results
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Fire Explosive Spalling ProtectionFire Explosive Spalling Protection
Test Results
With Steel Fibers – 15 minutes With Micro-PP Fibers – 2 hours
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Conclusions:Conclusions:
• Internationally proven to limit the occurrence of explosive
spalling.
• Recognized by designers, insurance companies and fire
Polypropylene micro- fibers are:
• Recognized by designers, insurance companies and fire
fighting authorities to:
•Protect the integrity of the concrete structure
•Mitigate damage and loss
•Protect lives of those trying to escape as well as those
fighting the blaze
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Polypropylene Polypropylene MicrosyntheticsMicrosynthetics
The most ProvedThe most Proved
and Tested Fibers for Concreteand Tested Fibers for Concrete
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Microsynthetic Fibers
Enhances all Concrete
Infrastructure Designed to last 50 to
100 YearsWater Treatment Plants Concrete Bridge Decks
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Traditional Concrete
Reinforcement
Concrete Slabs and Concrete Slabs and
Pavements On Grade
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Why Reinforce Slabs?
• Influence crack width and location
– Insurance against crack deterioration
– Insurance for extended joint spacing
– Not to prevent cracks
• Maintain slab surface tolerance• Maintain slab surface tolerance
• Poor soil conditions
• Impact and fatigue resistance
• Structural slabs on ground
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Proper Location of
Concrete Reinforcing
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Crack Width Variance
• Differential drying causes curling
• Cracks (joints) form in “V” shape
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Restraint of Crack at Top1-
1/2”
Min
• Place reinforcing as high as possible
– Top 1/3rd of slab thickness
• Minimum 1-1/2” cover
– Avoid plastic settlement crack above bar
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Wire Reinforcing Institute
• “Welded wire fabric keeps the cracked
sections of a slab closely knit together so that
the slab will act as a unit”
• “It has been emphasized that the primary • “It has been emphasized that the primary
purpose of welded wire fabric is to control
cracking -- not to prevent it”
• Only works if WWF is positioned in the proper
location
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Can Proper Positioning Of Secondary
Reinforcement Be Guaranteed?
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One Day We had a little Wind
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Wire Reinforcing InstituteWire Reinforcing Institute
• “Fabric half buried in the subgrade, has little
value”
• “It is impossible to “hook” fabric uniformly to
the desired location after the concrete has the desired location after the concrete has
been placed”
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Suggested Support Spacing Suggested Support Spacing
Welded Wire Reinforcement Range
Welded Wire Spacing
Suggested Support Spacing
W or D9 and larger 12” and greater 4-6 ft.
W or D5 to W or D8 12” and greater 3-4 ft.
W or D9 and larger Less than 12” 3-4 ft.
W or D4 to W or D8 Less than 12” 2-3 ft.
Less than W or D4 Less than 12” 2-3 ft.
(Wire Reinforcing Institute, Inc. - Tech Facts 702-R, 1998)
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Control joint spacing, L
L / 2 LongitudinalSteel Area, AsC
ontr
ol jo
int
Con
trol
join
t
IS
Subgrade Drag Formula
Concrete Weight
Friction, µ Induced crack
IS
Pot
entia
l cra
ck
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Subgrade Drag Formula
s
s
f 2 WL F
= Asf 2
As = cross-sectional area of steelF = subgrade friction coefficientL = distance between jointsW = weight of concretefs = reinforcing allowable stress (psi)
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ACI 360R – 10Recommended Control
Joint Spacing for Unreinforced Concrete
(Less than %As = 0.5%)
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ACI 360R - 10
3.2—Slab types
• 3.2.1 Unreinforced concrete slab
• 3.2.2 Slabs reinforced for crack width control• 3.2.2 Slabs reinforced for crack width control
• 3.2.3 Slabs reinforced to prevent crackingShrinkage Comp. & Post Tension Slabs
• 3.2.4 Structural slabs (ACI 318)Structural Concrete
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3.2.1 Unreinforced concrete slab
• “It is designed to remain uncracked between
joints due to loads on the slab surface and
restraint to concrete volumetric changes.”
• Adequate thickness to support loads
• Control joint spacing to handle shrinkage
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Concrete Reinforcement Spectrum
UN-Reinforced:
Micro – Synthetic Fibers
Light Gage WWF
Macro-Synthetic & Steel fibers
Rebar & Heavy WWF Sheets
Temperature/Structural
# 3 Rebar 18” OCEW
Temperature/Shrinkage Reinforced for
Crack Width ControlStructural
Steel Area Ratio [ Area of Steel / Gross Area of Concrete]
0 0.1% 0.2% 0.3% 0.4% 0.5%
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3.2.2 Slabs reinforced for crack width control
• “The primary purpose of the reinforcement is to limit the width of any cracks that may form at or between the joints. Bar or wire reinforcement should be stiff enough so that it can be accurately located in the upper 1/3 of the slab”. ACI Recommends 0.1% steel
• “Slabs may be reinforced with reinforcing bars, welded wire
reinforcement sheets, steel fibers, or Macro-polymeric fibers.”
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Concrete Reinforcement Spectrum
UN-Reinforced:
Micro – Synthetic Fibers
Light Gage WWF
Macro-Synthetic & Steel fibers
Rebar & Heavy WWF Sheets
Temperature/Structural
# 3 Rebar 18” OCEW
Temperature/Shrinkage Reinforced for
Crack Width ControlStructural
Steel Area Ratio [ Area of Steel / Gross Area of Concrete]
0 0.1% 0.2% 0.3% 0.4% 0.5%
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Design Criteria for Design Criteria for Design Criteria for
Fiber Reinforced Concrete
Macro Synthetic & Steel Fiber
Design Criteria for
Fiber Reinforced Concrete
Macro Synthetic & Steel Fiber
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Testing FRC
All typical test methods may be used with FRC; however, . . .
They may not show the effects of the They may not show the effects of the fibers.
Therefore, test methods have been developed to show effects of fibers . . .
In the plastic and hardened states. . .
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Committee 544 & 506:
- 544.1R; 544.3R; 506.1R
A 820 – Steel fiber spec.
C 1116; C 1399, C 1550;
C 1579; C 1609/M; New Syn. C 1579; C 1609/M; New Syn.
JSCE /JCI: SF 4 Equiv. Flex. Strength
TR-34 Re,3 - Eq. Flex Str. Ratio
YEILD LINE ANALYSIS DESIGN METHOD
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C 1399C 1399--0404, “Test Method for Obtaining Average Residual-Strength of Fiber Reinforced Concrete”
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Load
[(A+B+C+D) / 4] x l
ARS = -------------------------b d2
ASTMASTM C 1399C 1399
N
Average Residual Strength, ARS
With steel plate
lbs
0 0.5 0.75 1.0 1.25mm Deflection
A B CD
b d
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Mn = φφφφ As fy (d – a/2)
The Ultimate-Strength Design Methodology, used since the early 1960’s,
can be used to evaluate fiber reinforced concrete to conventional
reinforced concrete on the basis of the bending moments resisted by the
contained tensile elements in a unit of concrete.
Moment Capacity CalculationsMoment Capacity Calculations
Step by Step process:
Step 1: Calculate depth of rectangular stress block, “a”, using Equation 2.
a = Asfy/(0.85f’cb)
Step 2: Calculate the moment capacity of the continuously-reinforced section,
“Mn”, using Equation 3. Mn = φ As fy (d – a/2)
Step 3: Based on the required moment capacity, Mn, of the continuously-reinforced section, calculate the
required bending stress of the fiber-reinforced concrete section, “Fb” using Equation 4 fb = Mn/S This value
also represents the required average residual strength (ARS) of the fiber reinforced concrete section f’t. f’t =
fb
Step 4:This value can be found in the accompanying charts with the required fiber quantity
f’t =Mn/S
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Yield Line Slab Analysis
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ACI 360R 10: Chapter 11 –
Fiber-Reinforced Concrete Slabs-on-
Ground11.3.2.3 Flexural toughness—Flexural toughness of steel FRC is determined by testing
beams or panels in a laboratory using ASTM C1399, C1550, and C1609/1609M or JSCE
SF4.
11.3.3.3 Yield line method—11.3.3.3 Yield line method—
Yield line analysis accounts for the redistribution of moments and formation of plastic
hinges in the slab. These plastic hinge regions develop at points of maximum moment
and cause a shift in the elastic moment diagram. The use of plastic hinges permits the
use of the full moment capacity of the slab and an accurate determination of its
ultimate load capacity.
Provides Factors of Safety: on the basis of the location of the load with respect to the
edges of the slab. “Interior – Free Edge – Corner” Factors of Safety
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Steel Fiber Reinforced ConcreteSteel Fiber Reinforced Concrete
SFRCSFRC
Steel Fiber Reinforced ConcreteSteel Fiber Reinforced Concrete
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Steel Fibers Provide….… Crack Width Control
…Positive Positioning of Reinforcing
… Ductility
…Fatigue Endurance
…Impact Resistance…Impact Resistance
…Flexural Toughness
Re3 / ARS
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Tank reinforced with concrete & rebarTank reinforced with concrete & rebarthen subjected to live firethen subjected to live fireTank reinforced with concrete & rebarTank reinforced with concrete & rebarthen subjected to live firethen subjected to live fire
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Tank reinforced with concrete & steel fibers then subjected to same live fire Tank reinforced with concrete & steel fibers then subjected to same live fire
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Conventional Reinforcement
• Provides single point crack restraint
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Steel Fibers
• Provide continuous crack restraint
– From bottom of slab to just below surface
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Steel Fibers3 /
16”
• Restricts Joint Width
• Always Positioned
Correctly
• Joint Filler Stays in Place• Joint Filler Stays in Place
• Produce a More Stable
Joint
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ACI 360 table 11.1
Steel fiber concentration & residual strength factors
Fiber concentration, lb/yd3 Application (typical residual strength factors) re3
Anticipated type of traffic
over 33 Random Crack width control (20 to 40%)
Commercial and light industrial with foot traffic or infrequent lift trucks with pneumatic tires
33 to 50 Light Dynamic loading
Industrial vehicular traffic with pneumatic wheels or moderately soft solid wheels33 to 50 Light Dynamic loading
(30 to 50%)moderately soft solid wheels
40 to 60 Medium Dynamic Loading(40 to 60%)
Heavy-duty industrial traffic with hard wheels or heavy wheel loads
60 to 120 Severe Dynamic LoadingJoint spacing design(60% or higher)
Industrial and heavy-duty industrial traffic
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Steel Fibers
• Alternate System to Rebar in Slab On Grade Applications
• Alternate System to Conventional Reinforcement in Metal Decking.
• Uniform loaded slabs• Uniform loaded slabs
• Projects Where Joint Stability and Crack Control are Critical
• Superflat & High Tolerance Floors
• Heavy Commercial - Industrial Floors
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40 lbs. cubic yard of Novocon XR to replace #4’s @ 12’’ ocew
City of Sugarland, TX - August 2003
40 lbs. cubic yard of Novocon XR to replace #4’s @ 12’’ ocew
City of Sugarland, TX - August 2003
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2’’ Steel fiber overlay. Novocon XR @ 75 lbs. cubic yard
City of Houston / I-610 frontage roads
2’’ Steel fiber overlay. Novocon XR @ 75 lbs. cubic yard
City of Houston / I-610 frontage roads
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Blended Solutions
Novocon Steel Fibers or
Macro-Synthetic FibersMacro-Synthetic Fibers
+ Fibermesh Fibers
Novomesh System
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Mon
ofila
men
t
Fibr
illa
ted
HP
P
Fiber Reinforcement Product Positioning
Har
bour
ite Engineered Blends
Blended FRC Solutions
MICRO MICRO MICRO MICRO MACROMACRO
Mon
ofila
men
t
Fibr
illa
ted
Har
bour
ite
Plastic Shrinkage Cracking l Plastic Settlement Cracking l Lower Permeability l Shatter Resistance
Early Age
HardenedResidual Strength l Fatigue Resistance l Joint Integrity
Blended FRC Solutions
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ASTM C-1018 Flexural Toughness(Xorex: 20 lbs/yd3, Fibermesh: 1.5 lbs/yd3)
12
14
16
18
2 0
Loa
d (k
N)
2" Xorex Steel Fibre
2" Xorex Steel Fibre + Fibermesh
0
2
4
6
8
10
0 . 0 0 . 2 0 . 4 0 . 6 0 . 8 1.0 1. 2 1.4 1. 6 1. 8 2 .0
Deflection (mm)
Loa
d (k
N)
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A Blend of ASTM A820 Steel fiber
Microsynthetic -Monofilament
Commercial and Residential Markets
Providing Temperature and Providing Temperature and Shrinkage Reinforcement, not Structural
Not to be used to Extend Joint Spacing
24 pound bag (23 Steel + 1 PP)
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May 2003 - Galveston Conv. Ctr. – Specified 4’s @ 18’’. Used
36 lbs. Novomesh 850 cubic yard. Parking & Loading dock
May 2003 - Galveston Conv. Ctr. – Specified 4’s @ 18’’. Used
36 lbs. Novomesh 850 cubic yard. Parking & Loading dock
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Texas stores in 2007
Texarkana
Tyler
Longview
Mansfield
Conroe
Novomesh 850 blended steel fiber
Slab on ground – 24 lbs. cubic yard
Mezzanine CMD – 24 lbs. cubic yard
Loading dock – 36 lbs. cubic yard
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MACRO FIBER
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ACI 360R 10: Chapter 11 –
Fiber-Reinforced Concrete Slabs-on-
Ground
11.2 – Polymeric fiber reinforcement
11.2.2 - Design principals:– Micro-polymeric FRC design: same a unreinforced.– Micro-polymeric FRC design: same a unreinforced.
– Macro-polymeric FRC design : same as for Steel FRC
11.2.3 - Joint details:- Micro’s: same as for unreinforced s-o-g
- Macro’s: At 0.2 to 1% - increases post-cracking strength – therefore:
This material behavior permits wider sawcut contraction joint spacing; however, load transfer stability at sawn contraction joints should be considered carefully at wider joint spacing.
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Mn = φφφφ As fy (d – a/2)
The Ultimate-Strength Design Methodology, used since the early 1960’s,
can be used to evaluate fiber reinforced concrete to conventional
reinforced concrete on the basis of the bending moments resisted by the
contained tensile elements in a unit of concrete.
Moment Capacity CalculationsMoment Capacity Calculations
Step by Step process:
Step 1: Calculate depth of rectangular stress block, “a”, using Equation 2.
a = Asfy/(0.85f’cb)
Step 2: Calculate the moment capacity of the continuously-reinforced section,
“Mn”, using Equation 3. Mn = φ As fy (d – a/2)
Step 3: Based on the required moment capacity, Mn, of the continuously-reinforced section, calculate the
required bending stress of the fiber-reinforced concrete section, “Fb” using Equation 4 fb = Mn/S This value
also represents the required average residual strength (ARS) of the fiber reinforced concrete section f’t. f’t =
fb
Step 4:This value can be found in the accompanying charts with the required fiber quantity
f’t =Mn/S
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Yield Line Slab Analysis
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MacrosyntheticAlloy Polymer Macro
Synthetic Fiber
Alternate to 2.9 wire mesh and light duty rebar
Recognized By ACI Recognized By ACI 360R-06 Design of Slabs-on-Ground
Ideal for addition rates from 3 to 6#
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Notes: •Represents fiber dosages based upon yield stress - fy where fy = 75,000 psi for WWF and 60,000 psi for
• Reinforcement assumed at mid-depth of slab
• Contraction Joint Spacing per ACI Guidelines - See ACI 302 & ACI 360
• Slab Thickness based on project requirements per ACI and PCA guidelines for slab on ground design
•Chart values based on ASTM C1399 ARS Values
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Cracks in WWF Section with Joints
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Crack Width in # 3 Rebar Section
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Macrosynthetic Fiber: Crack Width
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City of Sugarland 6” street paving Fibermesh® 650
@ 3.5 lbs. pcy in lieu of #4 rebar @ 18” o.c.e.w.
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Macro – Micro Blend
The all-synthetic macro blend
Alternate to 2.9 wire mesh and light
duty rebar
Recognized By ACI Recognized By ACI 360R-06 Design of Slabs-on-Ground
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Comments:
• Represents fiber dosages based upon yield stress - fy where fy = 75,000 psi for WWF and 60,000 psi for rebar
• Reinforcement assumed at mid-depth of slab
• Contraction Joint Spacing per ACI Guidelines - See ACI 302 & ACI 360
• Slab Thickness based on project requirements per ACI and PCA guidelines for slab on ground design
• Chart values based on ASTM C1399 ARS Values
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Yield Line Slab Analysis
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Slidell, LA. Residential Streets – 5 lbs. 950. City of Slidell specifies 950 for streets
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Volta Manufacturing Gears Rd. Houston, TX Novomesh 950 – 5 lbs pcy / 5,000 cyds.
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Rivergate Scrap Metal
950@10lb/yd3
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Composite Metal Decking
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2007 ANSI - SDI C1.0 Standard for CMD2007 ANSI - SDI C1.0 Standard for CMD
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Texas Department of Transportation
DMS – 4550 FIBERS FOR CONCRETE
EFFECTIVE DATE: SEPTEMBER 2010
4550.1. Description. This Specification establishes
requirements and specific test methods to
Pre-Qualified Fibers for Concrete – Synthetic
Modified ASTM C1399:
requirements and specific test methods to
determine the dosage of fibers for Class A and B
concrete.
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Texas Department of Transportation
DMS – 4550 FIBERS FOR CONCRETE
EFFECTIVE DATE: SEPTEMBER 2010
1. Qualification. If approved for use by the Department, CST/M&P will add the material to the MPL.
2. Failure. Producers not qualified under this Specification may not furnish materials for Department projects and must show evidence of correction of all deficiencies beforereconsideration for qualification.
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Texas Department of Transportation
DMS – 4550 FIBERS FOR CONCRETE
EFFECTIVE DATE: SEPTEMBER 2010
4550.6. Material Requirements. Provide fibers conforming to ASTM C 1116, including synthetic fibers, that are alkali-proof, non-absorptive, resistant to deterioration due to long-term exposure to moisture or substances present in admixtures, and do not contribute to nor interfere with the air entrainment of the concrete. Steel fibers for nor interfere with the air entrainment of the concrete. Steel fibers for fiber reinforced concrete must conform to ASTM A 820, glass fibers must conform to ASTM C 1666, and cellulose fibers must conformto ASTM D 7357. In addition, the fibers and their dosage must meet the average residual strength requirements as listed in Table 1.
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Texas Department of Transportation
DMS – 4550 FIBERS FOR CONCRETE
EFFECTIVE DATE: SEPTEMBER 2010
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Texas Department of Transportation
Pre-Qualified Fibers for Concrete – Synthetic
Modified ASTM C1399:
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The Correct Fiber Fit for your Project
• Any Cast in Place Concrete
• Microsynthetic Fibers : Monofilament or Fibrillated
• Slabs & Pavement: w/ Close Joint Spacing using Light Gage WWF
• Microsynthetic: Fibrillated
• Slabs & Pavements: Using Heavy WWF or Light Duty Rebar (> w2.9)
• Macrosynthetic – Steel – Engineered Blends• Macrosynthetic – Steel – Engineered Blends
• Composite Metal Decking
• Macrosynthetic – Steel – Engineered Blends
• Heavy Commercial - Industrial Slabs & Pavements
• Steel Fibers – Engineered Blends
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Fiber Reinforced
ConcreteConcretefor theFutureFuture