Patent Application
20180141867
The present invention relates to concrete formulations for high mechanical performances in structural designs, fiber reinforcement special mix designs to limit or avoid steel rebars or pre-stressing. More specifically, the invention discloses concrete mix designs with high volumetric content of fibers and that the concrete contains different types of fibers to form a so-called hybrid fiber system.
Conventional fiber reinforced concrete technology is known, it has been described in various National and International Norms e.g. RILEM 162 TDF International), Model Code 2010 (International), CNR DT 204 (Italy SS 812310 (Sweden), TR63 (UK) ACI 318 (USA) ACI 360 (USA), DBV (Germany), DAFSTB (Austria). Fiber reinforced concrete mix designs containing different types of fibers have been for examples disclosed for example in WO 2011/053103 and more recently in CN102976697 and KR100940550. Such concrete are mainly used for pavement or deck repairs or to minimize the shrinkage of the concrete during hardening.
In WO 2011/053103, the main objective is to provide with a concrete to build large slabs, therefore, one property to be achieved is shrinkage resistance in order to avoid cracks formation. Therefore, shrinkage reducing agents, namely ethylene glycol, free lime or calcium sulfoaluminate, is used in combination with polymer fibers (synthetic fibers) whose role is mainly to reduce cracking due to shrinkage.
According to WO 2011/053103, the workability of the concretes is located in the classes F5 to F6, yet no data are disclosed concerning the workability retention (opening time) of the final concrete produced. Furthermore, no data and results are disclosed concerning the compressive and flexural strength of the concretes according to the invention.
Amongst others, one important disadvantage of the patent application WO 2011/053103 is the requirement to prepare a separate slurry containing water, cement and all shrinkage reducers and plasticizers (or water reducers admixture—namely powdered melamine or phosphonates), or fillers as well as fillers. The slurry is then added to the concrete prepared separately and the fibers are added.
A further important drawback of the invention according to WO 2011/053103 is the fact that the final placed concrete has to be cured using water after placing.
An additional drawback of the invention according to WO 2011/053103 is that the volume of paste is very low to ensure limited shrinkage and avoid cracking, thus reducing the scope of application and placement properties and well as the level of mechanical resistances that can be achieved, both in terms of compressive strength and in terms of flexural strength or ductility. Finally the document does not disclose water/total binder content (kg/kg) others than 0.42 and 0.46, which limits drastically the type of properties that can be achieved.
Relevant information related to Norms and normative tests mentioned in this patent application is described in Tables 1 and 2.
The present invention provides a concrete mix comprising sand, fine aggregates, binder, fibers, and various admixtures, having a consistency from S2 to SF3, a compressive strength in the range of 30-60 Mpa and a ductility represented by the following values:
The meaning of fc, ffl, fR1 and fR3 is the following:
fc is compressive strength, ffl is flexural strength, fR1 is strength for crack mouth opening 0.5 mm, fR2 is strength at CMOD 1.5 mm and fR3 is Strength at CMOD 2.5 mm.
The concrete mix of the invention is for slabs, floors or structural constructions with high ductility and workability retention.
The present invention proposes a solution to overcome the various drawbacks of WO 2011/053103. The concrete mix designs according to the present invention are not limited to shrinkage resistance enhancement using shrinkage reducers and synthetic fibers for this unique goal and true structural properties to be used in structural engineering for decks, bridges, pillars, etc. Also, the fiber reinforced fresh concrete mix designs according to the invention are engineered to comply with industrial production requirements, they are produced in conventional concrete mixing plants, can be transported over large distance since they have a high workability retention and do not need special curing techniques once placed.
Another embodiment is the concrete mix of the invention, further comprising coarse aggregates.
Another embodiment is the concrete mix of the invention, wherein the dosing of the Admixture system I is of 0.5-5% weight percent with respect to the binder content and the dosing of the admixture system II is of 0.1-2% weight percent with respect to the binder. This concrete mix is for high ductile thin slabs or floors with a consistency of S5-SF3.
Another embodiment is the concrete mix of the invention, wherein the dosing of the Admixture system I is of 0.1-1% weight percent with respect to the binder content and the dosing of the admixture system II is of 0.1-0.5% weight percent with respect to the binder. This concrete mix is for high ductile this slabs or floors with a consistency of S2-S4.
Another embodiment is the concrete mix of the invention, wherein the concrete mix comprises an admixture system III, wherein the third Admixture system III is obtained from a compound selected from the group consisting of cellulose microfibers, synthetic waxes, natural waxes, superabsorbing polymers, starch crosslinked polymers, acrylate crosslinked polymers, hexylene glycol (2-Methyl-2,4-pentanediol) and any combination thereof and the dosage of the admixture system III is of 0.3-6 weight percent with respect to the binder.
Another embodiment is the concrete mix of the invention, wherein fibers system C, comprising synthetic fibers, is added to the concrete mix.
Another embodiment is the concrete mix of the invention, wherein the dosage of fibers system C is of 0.02% to 2% volume with respect to the concrete.
Another embodiment is the concrete mix of the invention, wherein a part of the sand or the fine aggregates or the coarse aggregates are substituted by lightweight aggregates selected from the group consisting of expanded glass, expanded clay, pumice and expanded shale.
Another embodiment is the concrete mix of the invention, wherein the substitution rate for all aggregates (sand or/and fine or/and coarse aggregates) is at least 30% in volume.
The invention concerns special concrete mix designs to achieve any desired classes of compressive strength, while providing a high ductility and the fresh and hardened stages.
The ductility at hardened stages (28 days) is measured using flexural stress-strain measurement according to Norm EN 14561 (load increase needed to further opening the mouth size of the notch using a CMOD (Crack Mouth Opening Device)).
Table 3 indicates the resistances and ductility values expressed by the strength at various CMOD with respect to norm EN 14 561.
The concrete mix designs according to the invention contain at least 2 Fibers Systems A and Fibers System B that in combination provides the targeted mechanical properties. The Fibers System A contains only metallic fibers as described in Table 4:
The Fibers system A can be prepared with different types of metallic fibers corresponding to the characteristics indicated in Table 4.
The Fibers System B contains high strength fibers that are shorter than the Fibers of Fibers System A. and is described in table 5.
The Fibers System B can be made out of steels fibers, glass fibers, polyaramide (PA), carbon fibers and/or basalt fibers or any combination thereof.
The geometry of the none metallic fiber are normally straight whereas the metallic fibers in system B can be hooked end wire, straight slit sheet or wire, deformed slit sheet or wire, flattened-end slit sheet or wire, machined chip, melt extract, etc. The metallic fibers can be made of amorphous metal.
The fibers in System A are used to bridge macro-cracks and provide ductility by pull-out whereas the B type fibers have mainly the function to bridge micro cracks and delay the micro-cracks propagation with energy dispersion on pull out and further micro-cracking.
Preferably, the fibers in system A are hooked, with an ultimate resistance above 1100 MPa, preferably above 1300 MPa and even more preferably above 1500 MPa.
The ratio length divided by diameter (mm/mm) is typically located between 40 and 100, preferably between 45 and 95.
Preferably, the steel fibers in system B are hooked or straight with an ultimate resistance above 1100 MPa, preferably above 1500 MPa and even more preferably above 2000 MPa.
The ratio length divided by diameter (mm/mm) is typically located between 50 and 95 preferably between 55 and 90.
Preferably the fibers system B may contain non-metallic fibers like glass fibers, with a minimum strength of 900 MPa, more preferably over 1000 MPa and a minimum length of 12 mm. the fiber system B may also contain basalt fibers, preferably with a minimum strength of 2500 MPa and a minimum length of 12 mm. Both glass and basalt fibers used are straight.
Alternatively a third synthetic fibers System C can be added to the concrete mix according to the invention, for instance acrylic fibers, polyethylene fibers, polypropylene fibers, polyester fibers to enhance properties like fire resistance or intrinsic shrinkage. Alternatively, cellulose fibers may be used in fibers system C.
The concrete is designed to allow achieving the targeted performances in terms of strength, ductility, elasticity Modulus, placement and rheological properties, workability retention, etc.
The targeted properties are not only achieved by selecting the appropriate fibers mix design. The concrete formulation also plays an important role and is an integral part of the invention. The required ductility and mechanical properties are thus obtained by a combined effect of the concrete matrix and the special design of the hybrid fiber mix design.
Typically, the concrete according to the invention contains the following ingredients per cubic meter of produced concrete (Table 7).
The cement is typically CEM I, II and III, the fly ash is a conventional fly ash the sand is round or crushed sand, typically 0-4 mm and the fine or coarse aggregates are either round or crushed.
All ingredients of the final concrete are mixed using conventional industrial concrete mixers. The mixing time is conventional for about 30 seconds to some minutes.
According to the invention, the concrete mix has the following values of mechanical properties:
Preferably, the concrete mix of the invention contains:
A third optional third Fibers system C can be optionally used, whereas the fibers volume in Fibers system C ranges from 0 to 1.2 volume % of concrete.
More preferably, the concrete mix of the invention has the following characteristics:
The concrete mix of the invention optionally comprises:
Fibers in System B contains either 100% volume metallic fibers or 100% none metallic fibers, or a mix of metallic and none metallic structural fibers. Preferably the non-metallic fibers are glass fibers or basalt fibers or any mix thereof.
According to other embodiment of the invention, the concrete mix of the invention contains Fibers system C, a Fibers system A that is consisting of at least 2 different types of metallic fibers and a fibers system B that contains any mix or combination of high strength fibers metallic, organic, glass based, carbon based or basalt based.
The 3 admixture systems I, II and III used according to the invention are characterized below:
Admixture System I: Superplasticizing
This admixture system is a combination of at least two polycarboxylate ethers, with homo- or co-polymeric backbone, based on acrylic, methacrylic, maleic or allilic constitutional repeating units:
The dosage of the Admixture System I typically ranges from 0.05-5% solid content based on weight of total binder (total cement+total fly ash or slag+total silica fume) depending on the concrete placement properties targeted.
The ratio in weight (dry solid content) of the strong water reducer PCE and the workability retention PCE is typically located between 20:80 and 60:40 depending of the targeted application.
Admixture System II: Stabilizing
The stabilizer is a solid, a water solution, emulsion or dispersion of compounds such as:
The dosage of the admixture system B is typically located between 0.05-2.5% solid content based on weight of binder (total cement+total fly ash or slag+total silica fume), depending on the segregation risk related to the fibers and the workability retention targeted.
Admixture System III: Internal Curing
The internal curing agent: a solid, paste, a water solution, emulsion or dispersion of compounds such as:
The total dosage of the admixture system I and system II cannot exceed however the value of 5 weight % of the total binder.
The typical dosage of Admixture system III ranges from 0.05 to 6% solid content based on weight of binder depending on the conditions (size, temperature, relative humidity of the air, etc.).
Alternatively, the concrete mix of the invention may have a partial of full substitution of the sand and aggregates with lightweight sand and aggregates (expanded shale, expanded clay, expanded glass or pumice, natural puzzolans, etc.). This enables to obtain lightweight structural fiber reinforced concretes with densities below 1800 kg/m3, preferably below 1600 Kg/m3 or even more preferably below 1400 kg/m3.
The concrete mix of the invention may contain strength development accelerators, to reach 4-6 MPa resistance after a couple of hours. This is important for post treatment of slabs (helicopter finishing for instance) that can be done a couple of hours after the casting of the slab, thus saving time and improving efficiency.
The concrete mix of the invention may also include a retarding agent for instance and sugar modified structures, vinasses, molasses, or chelating agents, etc.
The concrete mix of the invention may use an air entrainer (like surfactants, soaps or hydrophobic compounds) to ensure a trapped volume of air from 2% to 15% in volume of the final concrete for freeze-thaw resistance or fire resistance depending on the application.
The general admixture System, consisting of the 3 Admixture Systems I, II and III not only enables to obtain a controlled workability over various classes (S1 to SF3), it also enables to perfectly disperse the high amount of fibers in the Fibers Systems A and B (and optionally in fibers System C) providing a very good stability of the fibers in the concrete matrix, avoiding 30 segregation of the fibers or bleeding of the none metallic fibers thanks to optimized mixing conditions. This explains why the concrete mix of the invention can be produced using conventional concrete mixing techniques.
There are many advantages associated with the concretes according to the invention as will be seen from the examples below.
The first advantage is that the combination of the concrete mix designs, the fiber mix designs (fibers systems A, B and optionally C) and admixtures systems (I, II and III) enables to overcome all the problems from the prior art and provide a wide range of consistencies, that can by managed and controlled by the 3 admixture systems I, II and II.
Furthermore, the invention provides concrete mixes having high volume of paste that can achieve very high shrinkage reducing and enables to cast very large slabs up to 3000 m2 without the appearance of cracks due to elevated ductility and resistances without having to use synthetic fibers that are weakening the resistance of the matrix and limits the applications. The combined usage of the high strength fibers system B and the admixture systems provides an optimum combination of shrinkage reduction and mechanical performances (compressive strength, flexural strength and ductility).
A further advantage of the invention is that the properties of the concrete paste, as the result of the combination of the paste content and the admixture systems, enable to use short (less than 40 mm) metallic fibers and/or high dosage of metallic fibers (over 70 Kg/m3 of concrete up to 165 kg/m3 of concrete) with no risks of segregation of without impacting the targeted consistency of the final concrete or the workability retention.
The concrete mix of the invention doesn't require special time consuming and costs ineffective curing actions, due to the presence when needed of the admixture system III, enabling self curing.
The concrete mix of the invention applies to wide range of construction elements, like slabs up to 3000 m2 without joints and without shrinkage cracks, floors, seismic applications, Insulated Concrete Frame for vertical walls, bridge segments, precast industry-tunnel lining segments, structural rehabilitation, etc.
The controlled rheology of the concrete mix of the invention enables building flat slabs or slabs with a designed slope.
The concrete mix of the invention has applications in large seamless thin slabs, floors and levels, bridges elements, concrete beams, concrete for impact resistance, seismic applications, etc. The concrete mix of the invention do not require any particular mixing processes or sequences and can be obtained in any dry of wet concrete batching plant.
One further characteristic of the concrete mix of the invention is that it provides consistency up to the SF3 self placing and self leveling consistency classes in a controlled manner through a sophisticated overall system of admixtures, and do not require any specific curing protection (water spraying, surface covering, etc.).
The concrete mix of the invention has high opening times or workability retention (period of time from the initial mixing of the ingredients during which the workability expressed by the consistency classes of the concrete S1-S5 and SF1-SF3 for self placing concretes) of the concrete does change, and remains in the same consistency class. The combination of the concrete mix design, the fibers mix design and the admixture system together enables to achieve the targeted improvements and properties.
Definitions
Various examples of mix designs and corresponding results are presented here according to the invention
This example with a low paste volume enable to achieve SF2 slump class (or consistency). In this example, only steel fibers are used in Fiber system B.
This other example uses only metallic fibers in Fiber system B.
This example shows an alternative according to the inventions with 2 different types of metallic fibers used in fibers system A and only steel fibers in Fibers system B.
This example uses only mineral fibers (basalt) in the Fibers system B.
Example of very high ductility concrete, with 2 types of high strength fibers in Fibers system B (steel and aramid).
Example according to the invention where the Fibers system B contains both metallic and glass high strength fibers.
This mix design according to the invention includes the Fiber system C with synthetic low resistance fibers (Polypropylene) specifically designed for fire resistance applications.
This final example shows an ultra high resistance concrete with very high ductility and full self placing consistency properties.
The mix design in example 8 combines 2 types of high strength fibers in the Fiber system a and 3 types of fibers (steel, glass and basalt) in the Fibers system B.
It is clear that the invention is not limited to the provided examples and that the selection of the various ingredients depend on the final application, placing and mechanical targeted properties and cost of the mix design.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2015/063045 | 6/11/2015 | WO | 00 |
