Focus Composite Materials

Construction Materials:
Chaitanya Raj Goyal

Composites Get Thumbs-up from the Industry

esearch and development do not necessarily yield positive results at every attempt. But, our race has tried, and tried hard over the ages, innovating and developing, rising from the ashes of failed attempts, overcoming the unyielding roadblocks in the path of our development, never giving up and finally making us reach this still unremittingly evolving current era. Definitely one of the greatest in the history of mankind! Throughout this development we have discovered and

invented many technologies, materials, products and processes. But, the day we conceptualized on exploring the possibility of manufacturing and integrating composites with our technology, we struck gold! The materials revolution, together with information technology and biotechnology is considered to be the major driving force of a new industrial paradigm. Advances in areas, such as the theoretical understanding of physical and biological matter, experimental techniques, and processing technology

have now enabled us to have composite materials designed to meet specific demands, and these are called the new, smart or advanced materials. In fact, with the technological leaps in recent times, focus has been on developing the materials required to perform in stringent conditions - high temperature & pressure, highly corrosive environment, higher strength but without much weight implications etc. which the conventional materials failed to service. Thus the construction industry,

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Focus Composite Materials

a largely material driven sector is also benefitting considerably from these advancements in the material technology. What is Composite Construction? A composite is when two or more different materials are combined together to create a superior and unique material. Thus Composite construction is a generic term to describe any building construction involving such multiple dissimilar materials. In civil engineering, composite construction exists when two

different materials are bound together so strongly that they act together as a single unit from a structural point of view. The parts of these composite members are rigidly connected such that no relative movement can occur. The first uses of composites date back to the 1500 B.C. when early Egyptians and Mesopotamian settlers used a mixture of mud and straw to create strong and durable buildings. Composite construction aims to make each material perform the function it is best at, or to strengthen a given cross section of a weaker material. The main components of composites are reinforcing agents and matrix. The fibers, particulates & whiskers act as the reinforcement and provide most of the stiffness & strength. The matrix binds the reinforcement together thus effecting the load transfer from matrix to reinforcement. Other substances such as fillers are used to reduce the cost and improve process ability & dimensional stability. Fiber reinforced composites can be further divided into those containing discontinuous or continuous fibers. Another commonly practiced classification is by the matrix used: polymer, metallic and ceramic. Most commonly used reinforcements include glass, carbon and aramid fibers, these being available in a variety of forms (continuous, chopped, woven & non-woven, multi-axial) as well as combinations of these. Careful selection of reinforcement type enables finished product characteristics to be tailored to almost any specific engineering requirement. Glass fiber is by far the most widely used fiber reinforcement and hence the terms "GRP" (glass reinforced plastic), "Fiberglass" and "FRP" (fiber reinforced plastic) are often used to describe articles fabricated from composites particularly for application in civil engineering. Why Composites? Engineers can utilize over 50,000 materials for the design and manufacture of engineered products, including metals, polymers, ceramics, and composites. While metals and polymers are

currently the dominant materials for engineering applications, composite utilization is gradually increasing due to superior strength, low weight, and improved thermal and electrical performance characteristics. Composites are also ideal for use in the construction industry because of their dimensional stability, impact resistance, low flammability (with the appropriate mix of resins and additives), low maintenance and design flexibility. Lower composite manufacturing costs would accelerate this trend, especially in cost-sensitive industrial mass markets. As an example of superiority of composite materials such as fiber reinforced polymers or glass reinforced plastics over the conventional ones, we can compare a carbon fiber reinforced composite with its steel counterpart. The carbon fiber composite can be five times stronger than high grade steel while having only one fifth the weight. Aluminum (specific grade) is much nearer in weight to carbon fiber composite (though still somewhat heavier), but the composite can have twice the modulus and up to seven times the strength. Structures made of composite materials have long service life and are unaffected by rain, frost and salt, requiring cosmetic attention only. Maintenance costs are therefore lower than those for similar structures in traditional materials such as concrete, steel and wood. Composite profiles can be machined as quickly and easily as wood - on equipment fitted with diamond tooling. Also due to their light weight the structural members can be made in the factory and then transported to the installation site. There they can be erected on prepared foundations in a matter of hours. Installation can also be done at night, causing negligible disturbance to road or rail traffic. Highspeed structure installation means minimal noise and traffic disruption along with significant cost savings. Application of advanced composites in civil infrastructure Such materials have been used in the industry since long (couple of de-

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Focus Composite Materials

Carbon fiber reinforced tube

cades), especially in the developed countries. But the applications have varied, improved and widened over the time with research based progress and composites have kept surprising the engineers time to time through their growing potential and tremendous abilities. With the completion of every successful project, they have gradually found their way into various civil engineering fields for good! These applications range from non-structural gratings and claddings to full structural systems for industrial supports, buildings, long span roof structures, tanks, bridge components and complete bridge systems. Their benefits of corrosion resistance and low weight have proven attractive in many low stress applications. An extension to the use of high performance FRP in primary structural applications, however, has been slower to gain acceptance although there is much development activity. Composites present immense opportunities to play increasing role as an alternate material to replace timber, steel, aluminum and concrete in buildings. The contribution of composites can be divided into two parts as in, the rehabilitation of the existing structures comprising of their repair, strengthening and retrofitting, and applications in new construction. Fiber reinforced concrete is one such wonder composite. Fiber reinforcement is mainly used in Shotcrete, but can

also be used in normal concrete. Fiber reinforced normal concrete is mostly used for on-ground floors and pavements, but can be considered for a wide range of construction parts (beams, pillars, foundations, etc.), either alone or with hand-tied rebars. Concrete reinforced with fibers (which are usually steel, glass, or plastic fibers) is less expensive than hand-tied rebar, while still increasing the tensile strength many times. Steel is the strongest commonlyavailable fiber, but the premium fibers are carbon reinforced plastic fibers, which are nearly as strong as steel, lighter-weight, and corrosion-proof. FRC is also used in construction of domes, curtain walls, parapets etc. Reinforcement in concrete structures has become another important application of composites. Over the last decade, considerable attention has been devoted to the development of composites as alternative reinforcement for concrete in place of conventional steel rebar and tendons. A significant amount of this effort stems from the First world research community, especially in the development of carbon fiber and aramid fiber based reinforcing elements ranging from round and deformed (spirally wound) bars to ribbon like elements and even grids. Carbon fiber based tendons and cables are increasingly being used globally for reinforcement of concrete

structures required to exhibit high performance. With easier field installation compared to steel, these elements also cause significantly less sag under their own weight, which increases load capacity while enabling the construction of longer bridge spans. Carbon fiber composite cables (CFCC) are a good example of such elements. The fiber is used in prepreg tow form that is stranded to make a primary strand. The surface of the strand is specially coated. Then multiple strands are used to form a twisted cable. Once the strands are twisted together, the entire assembly is heated to cause adhesion between the coatings and resin around individual strands. CFC cables have been extensively used for pre- and post-tensioned concrete structures, external post tensioning of wooden members and as earth anchors. The cables are also available in the form of shear reinforcement and as continuous spiral hoop reinforcement for columns. Aramid fiber reinforced composites have also become increasingly popular in the industry because of their high toughness/tenacity, high elongation at break (significantly exceeding that of carbon fiber based elements) and nonmagnetic /nonconductive characteristics. Glass and aramid FRP rods for pre-stressing and as tensile reinforcement in structures have also been used and turned out to be a successful experiment. Thus FRP composites can be used as combined permanent shuttering and tensile reinforcement in concrete structures under the designed guidelines. Aramid fiber based linear reinforcing elements have been used in a large variety of applications in structures ranging from bridge decks and girders to precast irrigation channel sections. NEFMAC, or New Fiber Composite Material for Reinforcing Concrete, is made from glass, aramid, or carbon fibers (or combinations of each) impregnated with an appropriate resin system, such as polyester, vinylester or epoxy to form a grid. NEFMAC grids have been used in tunnels, runways and aprons for airstrips/tarmacs, roads,

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Larsen & Toubro Ltd

Focus Composite Materials

buildings, channels, rehabilitation, and for general architectural elements. They are often used as lightweight reinforcement in building fascia and curtain walls, where the lower requirements for cover applications result in thinner and lighter panels. Due to their non-magnetic properties, these grids have been used as reinforcement in hospitals and in free-access floors, as well as in sensitive structures such as scientific laboratories and observatories. In coastal areas and regions where rapid corrosion of steel reinforcement is a concern, NEFMAC elements can be used by themselves or in combination with heavier steel bars. Also, composite ground anchors consisting of cables or rods connected to a bearing plate are often used for the stabilization of steep slopes or slopes consisting of softer soils, as well as the enhancement of embankment or foundation soil capacity, or to prevent excessive erosion and landslides. They have excellent advantages over the conventional steel anchors. Fabric reinforcement for rehabilitation and retrofit of existing structures is perhaps one of the most required and appreciated uses of the composites. The industry faces a critical need to retrofit and rehabilitate its civil infra-

structure ranging from buildings and parking structures to bridges, tunnels and irrigation channels due to their incapability to handle current loads or requirements, existing deformations, cracking, corroded reinforcement, etc. The use of fiber-reinforced composites presents an attractive option in such cases due to their enhanced mechanical performance, environmental durability, corrosion resistance, light weight and rapid application potential. Some composite based solutions include the use of fiber tow through the wet-winding process but it is restricted to use on chimneys and some columns. Its use is decreasing in favor of another process, which consists of the external placement of fabric sheet forms onto the surface of the structural element to be repaired/ retrofitted. This process has been used extensively, primarily with carbon fiber, and to a lesser extent with aramid fibers. Applications range from use on columns, floors, beams and slabs in buildings, girders and deck soffits of bridges, to use on chimneys, retaining walls, tunnel linings and other concrete structural elements. In addition, the fiber sheet material has often been used as a protective coating for aging and deteriorating material as a preventive measure.

Looking Forward The world's energy system is bound to change rather radically in the upcoming decades. New, efficient and clean technologies will have to be introduced since the scale of what needs to be done is nerve-racking. In this context, we need to encourage breakthroughs and radical ideas, since incremental progress in existing solutions may not be enough. To make real progress, we must create an environment in which high-risk, high reward research is encouraged. Materials research is probably the most important element for the development of the necessary technologies needed to provide a clean, reliable supply of efficient energy. Today, the composites marketplace is widespread. Material science research has taken off in India in recent years, but the research is still confined to academic level. Application oriented research is minimal. Substantial activity takes place within the theoretical area though. The preferred areas of collaboration with major countries were superconductivity, metals & alloys, and electronic and magnetic materials. The collaboration appears to be driven more by academic interest and opportunities rather than by any consideration of national priorities for India. As most of the markets across the globe continue to grow, composites have found their place in the world and seem to be gaining market share, especially in products where performance is critical. Some of these products are very new, but isnt it interesting that construction is still a major market for composites, just as it was in 1500 B.C. when the Egyptians and Mesopotamians were using straw to reinforce mud bricks. Additionally, composites are on the path towards being more environmentally friendly. Resins will soon incorporate recycled plastics and biobased polymers. Composites will continue to make the world lighter, stronger, more durable, and a better place to live. Photo Courtesy
www.buildipedia.com, www.metrocrete.com

Glass fiber reinforced concrete

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