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Use of steel fiber reinforced concrete

has advanced substantially in the last decade

Applications of Steel Fiber


Reinforced Concrete
S
tee1 reinforcement in the Technical background bridge decks exposed to deicing
form of mesh and bars was chemicals, sea walls, and precast
Engineers, testing laboratories, uni-
first patented in France by versities, concrete producers, and concrete breakwaters attest to the
Joseph Monier in 1867. Steel superior durability of SFRC.’
fiber manufacturers have tested
fibers, as we know them today, Steel fibers rust only on the con-
SFRC for various physical proper-
were first patented in the United crete surface. The amount of sur-
ties. Concrete reinforced with steel
States by James Romualdi and Bat- face oxidation is very minimal, since
fibers that meet ASTM A 820 stan-
telle Development Corporation in the composite is about 99 percent
dards for Type I cold drawn
1962. Besides Romualdi’s work, re- crimped wire segment with an aver- concrete and insulates the individ-
search in the early 1960s by Batson, ual discrete fibers with a passive
age tensile strength of 180,000 psi
Heneger, Lankard, Ramakrishnan, skin of cement paste. The surface
(1200 MPa) can have up to twice
Shrader, Shah, Swamy, Zollo, and oxidation has no structural effect,3.’
the modulus of rupture, shear
many others has led to industry ac- and the only cosmetic discoloration
strength, torsional strength, and fa-
ceptance of steel fiber reinforced is an occasional surface freckle.
tigue endurance; up to 1.4 times the
concrete (SFRC) for many applica- The corrosion behavior of SFRC
abrasion and erosion resistance; and
tions. Through their dedicated re- is very different from concrete rein-
up to 5 times the impact energy ab-
search, SFRC has matured into a forced with steel bars. Galvanic
sorption of plain concrete.
proven concrete building material. corrosion in reinforced concrete de-
Most steel fibers on the market
Throughout the ages, material pends on the development of elec-
today have little effect on the mod-
engineering seems to parallel at- trochemical corrosion cells in which
ulus of elasticity, creep, poisson’s
tempts at stopping and evading the the steel forms a conduit along
ratio, compressive strength, and
consequences of structural cracks. which electrons migrate from the
electrical conductivity. Adding steel
Most of this engineering was, and is anode (where the corrosion takes
fibers at the rate of 17 to 150 lb/yd’
today, empirical. Concrete design- place) to the cathode.
(10 to 89 kg/m3, or up to 1.1 per-
ers noted that cracks occured at A corrosion cell can develop
cent volume) slightly increases the
certain stress points, and in their whenever sufficiently dissimilar
density of concrete. Curling of
next design used more reinforcing conditions exist to produce a cath-
, SFRC slabs on grade for a given ce-
to stop it. ode and an anode. It is much easier
ment factor, water content, and
Concrete is the number one for one large corrosion cell to de-
slab thickness is not much different
structural material in the world, velop incorporating a section of re-
than for equivalent plain concrete
with annual production of over six bar that is continuous over a rela-
exposed to the same thermal and
billion tons. For a variety of rea- tively long distance than for many
moisture gradients. ’
sons, much of this concrete is small corrosion cells to develop in-
cracked. The cause of concrete Durability corporating discrete steel fibers.
cracks can be structural or eco- Fibers in general do not change the Also, when fibers do corrode they
nomic, but many cracks are due to permeability that is due to con- do not exert a strong enough ex-
the inherent tensile weakness of the crete’s porosity, but do decrease the pansive force to disrupt the con-
material. As concrete shrinks, and if permeability that is due to crack- crete.5,6 Consequently, SFRC re-
it is restrained, it will crack. Steel ing. Steel fibers prevent micro- mains strong even at the surface
fiber reinforcement offers a solu- cracks from becoming working where corrosive elements permeate.
tion to the problem of cracking by cracks, and thus protect the porous With concrete containing both
making concrete tougher and more concrete from further aggressive steel fiber and conventional rein-
ductile. environmental attack. Numerous forcement, called fiber reinforced-

I 44 Concrete International
Fig. 1 - SFRC placed ustng laser screed.

reinforced concrete (FR-RC), duces the slump. However, varia- screeds, commonly used for flat
cracking of the concrete cover over tions in weather conditions, air work. The laser screed is very effi-
the structural steel rebars is con- content, aggregate gradations, and cient for placing and finishing very
trolled by the steel fibers. moisture content play a much more large volumes of SFRC (Fig. 1).
important role in altering slump in When the concrete is vibrated or
Mix proportions a batch-to-batch comparison’ than floated, the steel fibers sink down in
The above-mentioned advantages of addition of 17 to 100 lb/yd3 (10 to the slab, leaving a virtually fiber-
SFRC assume that good concrete 59 kg/m’) of steel fibers. When de- free surface. When using internal
mixes employing proven concrete signing a fibrous concrete mixture vibrators, one may have to make
materials are used. The use of 17 to with a given set of materials in ac- changes in the vibrating methods to
100 lb/yd3 (10 to 59 kg/m3) of cordance with AC1 211, the slump minimize fiber-free zones. When
crimped cold drawn steel wire seg- can be very stiff at 0 to 2 in. (o to pumping SFRC, rubber elbows in
ment fibers normally does not re- 51 mm) or plasticized to 6 to 10 in. the lines should be avoided and steel
quire major mix adjustments. When (150 to 250 mm). elbows used instead; flexible lines
higher fiber concentrations are Even though it is widely used in are fine for the end discharge lines.
used, a fiber factor mix proportion the field, the uniformity or repeata- SFRC can be finished using con-
adjustment is sometimes necessary bility of the slump test is not pre- ventional techniques. Most surface
to accommodate the higher surface cise. ASTM C 143,“‘Test Method textures attainable with regular
area of the fibers with additional for Slump of Portland Cement concrete can be obtained with
cement paste. Normally it is neces- Concrete,” does not have a preci- SFRC, including floated, broomed,
sary for quality control (QC) pur- sion statement. In “Interpreting the jitter bugged, roller bugged, slip-
poses to proportion a mix to meet Slump Test,” Jim Shilstone writes, formed, roller compacted, dry
compressive strength requirements. “It should be constantly recalled shake hardened, shot textured,
This is equally true for SFRC, even that the slump test is merely an in- formed, and stamp patterned, as
though the fibers contribute little to dicator of batch consistency. Noth- well as any number of hand and
compressive strength. When adjust- ing more should be interpreted.“* machine trowelled or burnish fin-
ments are necessary it is always This is equally true of SFRC. ishes. Tyned and burlap-dragged
practical to rely on the local con- finishes require some adjustments in
crete producers quality control en- Mixing, placing, finishing finishing technique so as not to rake
gineer. When a QC engineer is not Most SFRC uses ordinary mixing, fibers across the surface (e.g., tilt-
available, follow AC1 211 to adjust placing and finishing methods and ing a tyning rake at 30 degrees will
for workability, placeability, ap- equipment. usually produce a satisfactory fin-
pearance, and strength. Fiber fac- Steel fibers can be added before, ish). Vibrating screeds, magnesium
tor adjustments are necessary when after, or during the batching se- bull floats, and magnesium hand
using 2 in. (51 mm) steel fibers in quence of charging the concrete floats are essential tools for achiev-
quantities exceeding 100 lb/yd3 (59 materials. If balling occurs, it is ing a variety of desired SFRC fin-
kg/m3) that affect consistency or usually eliminated by altering the ishes. At higher fiber concentra-
slump. batch sequence much in the same tions, dry shake hardeners are an
manner that concrete producers effective means of providing a non-
Slump eliminate cement balling. fiber finish. For steel fiber rein-
Some researchers look at slump as Placing SFRC may require a little forced shotcrete (SFRS), a plain fi-
an exact measure. Many also report more energy, but SFRC responds nal flash coat is effective in produc-
that adding fibers to concrete re- well to wet screeding and vibratory ing a regular finish.

November 1991 45
1 .o
the widest creek
0.9 of each specimen
is shown G erperlmental :-esults
I-- -._-- 0 r e s u l t s f r o m t h e
0.8 theoretlcul analysis

-c 0.7
E
II 0.6 -
D
r 0.5
1
-1

-i 1 6 -;

- 8

t!me ( d a y s )

Fig. 2 - Crack width versus time for various fiber Fig. 3 - Average crack width versus steel fiber volume
volumes. oercentaaes.

Toughness structure cracks, the cracks are mi- SFRC is placed in a form, basically
“Toughness” is a good term for cro in size, or small enough to make a box with four sides and a bottom,
them invisible and acceptable in the fibers align along the thinnest
describing the post-crack behavior
of SFRC and what steel fibers do to width. section, which is where the rein-
strengthen concrete. Different au- In research reported in 1990, forcing is needed the most to resist
thorities define toughness in differ- Grzybowski and Shah confirmed cracking.
ent ways: the Japanese Concrete In- that small amounts of steel fibers Fig. 4 illustrates the difference
“ . . . can substantially reduce crack between the distribution of fibers
stitute defines toughness in absolute
terms as the energy required to de- widths due to restrained drying and rebar in slabs. In the middle of
flect a FRC beam to a midpoint de- shrinkage.“” Fig. 2 shows reduc- a section of mass concrete the fi-
flection of 11150th of its span; tion in crack widths as the fiber bers are oriented randomly, but in
ASTM C 1018 defines toughness as volume increases from 0.25 to 1.5 a slab the fibers tend to orient
the energy equivalent to the area percent. It is interesting to note that themselves horizontally, especially
under the load deflection curve up the starting time of cracking is de- in the top and bottom surfaces.
to a specified deflection. Cold layed as the fiber addition in- This is due to the placing and fin-
drawn steel crimped wire fiber, creases. Fig. 3 illustrates that the ishing operations in flatwork, which
when tested according to ASTM C average crack widths versus plain knock the fibers down into a hori-
1018, typically produces Toughness concrete are reduced 80 percent zontal position, and to the effect of
Index values of Is = 3 to 5, I,, = 5 with only 0.25 percent fibers. Even gravity. This automatic horizontal
to 9 and ZjO = 11 to 21, depending at these small percentages steel fi- alignment contributes to the ability
on the type, amount, and length of bers increase the tensile strain ca- of fibers to control cracking at the
fibers.9 pacity enough to substantially stifle slab surface.
crack propagation. Replacing non-structural conven-
Crack resistance Grzybowski and Shah used tional steel rebar or wire mesh with
straight steel wire fibers. Crimped SFRC eliminates the time consum-
The efficiency of fibers in arresting
concrete cracks was reported by or deformed steel fibers with better
Grzybowski in 1989.‘O He con- mechanical anchoring and bonding
cluded that the replacement of con- properties would likely show supe-
ventional rebar with fiber reinforce- rior performance in crack resistance
ment has many structural advan- effectiveness.
tages, particularly where cracking is Fiber orientation also plays an
independent of loading. The reason important role in minimizing crack-
is that with fibers the internal ing of concrete. Soroushian and
stresses are much more evenly dis- Lee” concluded that steel fiber effi-
tributed throughout the cross sec-
tion of the structure and along the
length of the in-place concrete.
With conventionally reinforced
ciency is due to a preferential align-
ment. In their study they discovered
more fibers wherever a boundary
+l-fJz$y
exists. At the job site a boundary
concrete, large visible cracks occur. would be a finished or formed out- Fig. 4 - Comparison of fibers and
Even if a fiber reinforced concrete ermost concrete surface. When rebar in slabs.

46 Concrete International
Pockets,
Voids 8
Shadows

Fig. 5 - Comparison of fibers and rebar in shotcrete. Fig. 6 - Replacing wooden tunnel lining with SFRS.

ing work of placing rebars and cuts throughout the entire shotcrete force the dolosse, but the pounding
down on construction time. This mass, thus allowing for thinner sec- surf caused the concrete cover over
time savings along with the ability tions on very irregular surfaces as the rebar to crack, leading to salt
to produce concrete with smaller shown in Fig. 6. water intrusion and accelerated cor-
(and in many cases no visible) A typical blasted rock tunnel is rosion of the rebar; within a few
cracks is why SFRC is becoming very irregular and it is difficult to years 80 percent of the rebar units
more widely used. bend bar or mesh reinforcement to disintegrated. The Corps has moni-
the contours of the surfaces. With tored these SFRC units periodically
Practical applications SFRS a uniform steel reinforced and have found them to be struc-
shotcrete can be quickly applied as turally sound and durable in this
Shotcrete support lining. SFRS has been suc- harsh environment. After 14 years
Shotcrete mixes are generally over- cessfully used to repair dams, spill- exposure in the Pacific Ocean, the
sanded and therefore require high ways, spilling basins, caisons, bulk- Corps concluded that “.. . the fiber
cement percentages, which leads to heads, culverts, piers, locks, in- reinforced concrete is in good con-
increased shrinkage cracking. Also, verts, piles, columns, water tanks, dition. No visual signs of fiber cor-
thin section shotcrete on irregular aqueducts, tunnels, and refracto- rosion were evident.“4 Other simi-
surfaces, much of which is placed ries. The successful repair work has lar applications of SFRC precast
vertically and is difficult to prop- led to SFRS specifications for new units confirm this durability.
erly cure, has a high tendency to construction of the same group of Many different sizes and shapes
crack. Steel fibers are an economi- structures. of precast units are utilizing SFRC
cal and practical way of reinforcing to eliminate congested steel rebar
both wet and dry mix shotcrete to Precast concrete and mesh. The mining crib block
control cracking. Precast concrete producers are us- industry has used steel fibers since
In Fig. 5 the differences between ing SFRC to eliminate pattern the 1960s for post-failure tough-
two methods of reinforcing shot- cracking, reduce chipping and ness. SFRC crib blocks do not
Crete are compared, one with steel cracking in handling units, increase crumble like ordinary concrete and
fibers and the other with rebar. performance in corrosive environ- offer greater safety and economy in
When shotcreting through rebar or ments, resist thermal shock and im- mine roof support systems. Many
wire mesh reinforcement, air voids, pact, and minimize cracking in other SFRC precasters are develop-
sand pockets or what are com- casting beds. ing. innovative applications that
monly called “shadows” occur. The precast dolosse (twisted H perform better at lower costs.
Shadows can lead to pattern sur- units) in Fig. 7 show what can be
face cracks and corrosion prob- done with SFRC. In the 1970s the Concrete slabs
lems. Time consuming attention by U.S. Army Corps of Engineers used The primary SFRC slab applica-
experienced nozzlemen is needed to 80 to 120 lb/yd3 (47 to 71 kg/m3) of tions are for factory floors, indus-
correctly place shotcrete around re- steel fibers as the only reinforce- trial floors where damaging dy-
bar. With SFRS, the reinforcing is ment in these massive, 42-ton (38 namic and concentrated loads re-
shot with the concrete, thus elimi- Mg) units. When transported to the quire added reinforcing, commercial
nating the shadow problem6 and breakwater site, only two out of the floors where crack and fatigue re-
speeding up production. SFRS pro- 600 units fractured. The Corps also sistance is needed, and composite
vides more uniform reinforcement tried conventional rebar to rein- metal deck/SFRC floors. Pavement

November 1991 47
uses include highways, roads, park-
ing areas, bridge decks, thin-bonded
overlays, airport runways, taxi-
ways, aprons, and truck weight sta-
tions.
Industrial floors
Most industrial and commercial
slabs-on-grade are subjected to se-
vere conditions. One such slab, a
manufacturing distribution center in
Missouri, used 33 lb/yd3 (20 kg/m3)
of steel fibers in a 5 in. (127 mm)
thick 4000 psi (28,000 kPa) 240,000
ft2 (22,300 m*) SFRC slab with a
monolithic traprock hardener. Dis-
charge of the concrete together with
the reinforcement directly from the Fig.7 - Precast SFRC breakwater Fig. 8 - Thin bonded SFRC overlay
truck produces savings in labor and units for jetty in California. on I-610 in Houston, Texas.
equipment: to the ready mixed con-
crete producer it means better turn
around time efficiencies of their off and spall, conclusion number 16 Loma Prieta Earthquake lasted 15
$lOO,OOO+ trucks; to the contrac- of the report on the test overlay seconds and tested the Stanford
tor it means time saved by eliminat- states “... the fiber sections proved Linear Accelerator, which used 80
ing the step of placing reinforcing to be far superior in their ability to lb/yd’ (47 kg/ml) of steel fibers as
steel and chairs. The workplace is control longitudinal and transverse the only reinforcing in the 4 in. (100
also safer, with no reinforcing steel cracking.“13 Notice in Fig. 8 that a mm) thick [two 2 in. (50 mm) lifts]
to trip over. tyned finish is attainable and main- shotcrete tunnel lining. The 9000 ft
SFRC slabs on grade should be tains a skid resistant surface with (2700 m) long tunnel survived the
engineered floors with the proper little or no cracking. 7.1 earthquake without any struc-
attention devoted to subbase prepa- tural damage, even though the ac-
ration, concrete mix design, and a Metal deck/SFRC floors celerator was knocked out of align-
thorough analysis of loading condi- Steel framed buildings are using ment and several million dollars
tions. Industries recognize the steel fibers for shrinkage/tempera- worth of repairs to the equipment in
toughness of SFRC floors for as- ture control in concrete slabs on the tunnel were required.
suring minimal costly downtime re- metal decks. Typically the steel fi- For earthquake resistant struc-
pairs. bers are replacing light gauge tures, SFRC produces a more dam-
welded wire fabric as secondary re- age tolerant concrete, particularly in
Pavements inforcement. SFRC is gaining ac- areas where the steel rebar is highly
Steel fibers have been used success- ceptance among architects, struc- congested at beam column joints in
fully in millions of square feet of tural engineers, owners, contractors buildings. During an earthquake,
pavements for: roads, highways, and developers. Steel fibers offer conventional reinforced concrete
bridges, and air fields. Early con- the structural integrity of the steel first loses the concrete cover over
cerns with joint spacing, curling, mesh it replaces, plus the added the rebar. Pieces of concrete
and exposed fibers have been over- benefit of being more efficient and wedged in between the rebar crum-
come and remedied by fine tuning ductile. Whenever floors are sub- ble and fall out, causing a loss of
design thickness, joint procedures, jected to high frequency repetitive stiffness and structural integrity.
and finishing techniques.’ One such loadings, specifying steel fiber With SFRC there is very little spall-
test pavement that has been closely quantities that can handle the loads ing, and much more energy is
monitored is Interstate 610 Loop will increase their endurance limits needed to lose the concrete wedged
South in Houston, Texas, where 2 and longevity. Metal deck/SFRC in between the rebar. In SFRC the
and 3 in. (50 and 75 mm) thick floors are not only more crack re- fibers add a toughness that main-
bonded overlays containing 85 sistant but safer and more econom- tains better structural stiffness. This
lb/yd3 (50 kg/m3) of steel fibers ical. Fig. 9 shows a typical metal- added ductility of SFRC makes
were placed over a severely cracked deck/SFRC project where the safer buildings in earthquake zones.
existing concrete in 1983-84. Peri- SFRC was pumped through 300 ft
odic evaluation surveys indicates (91 m) of hose. C$f;;ommonapplications
good performance of the fibrous
concrete with virtualy no micro- Seismic structures With slurry infiltrated fibrous con-
cracking along longitudinal saw-cut Living in earthquake zones makes crete (SIFCON), preplaced fibers
joints. Whereas the pavement rein- one more conscious of the test a are grouted, usually in precast
forced with steel mat shows D- structure goes through during a se- forms employing a vibrating table.
cracking that will eventually chip vere ground shaking. The 1989 Up to 25 percent by volume of fi-

48 Concrete International
2. Whalin, R.W., “Examination of Con-
crete Cores from Dolosse, Humbolt Bay
Jetty,” U.S. Army Corps of Engineers
Structures Laboratory Report, July 21, 1986.
3. AC1 Committee 544, “State-of-the-Art
Report on Fiber Reinforced Concrete,” (AC1
544.IR-82) American Concrete Institute, De-
troit, 1982, 22 pp.
4. “Fiber Reinforced Concrete,” Portland
Cement Association, Skokie, Feb. 1991.
5. Baun, M.D., “Use of Steel Fiber Rein-
forced Concrete as a Bridge Deck Overlay
Alternative,” State Transportation Engi-
neering Conference, Columbus, Ohio, Nov.
1990.
6. Morgan, D. R., “Developments in
Shotcrete for Repairs and Rehabilitation,”
Concrete Construction, Sept. 1991, pp. 661-
664.
7. Shilstone Sr., James M., and Shilstone
Jr., James M., “Customize Every Concrete
Batch with Computers” Concrete Construc-
Fia.10 - SFRC was oumoed uo to 300 ft for this metal deck/SFRC floor. tion, V. 36, No. 6, June 1991, pp. 477-479.
8. Shilstone, J.M., “Interpreting the
Slump Test,” Concrete International: De-
sign & Construction, V. 10, No. 11, Nov.
bers can be incorporated using this of placing concrete with typical 1988, pp 68-70.
technique; with these high steel fi- grading and paving equipment. 9. Ramakrishnan, V.; Wu, G.Y.; and
ber volumes the concrete acts more However, RCC is difficult to rein- Hosalli, G., “Flexural Behavior and Tough-
like steel with very high compres- force with conventional rebar. Steel ness of Fiber Reinforced Concretes,” Paper
No. 880094, Transportation Research Board
sive, tensile, flexural, and shear fibers offers a simple, effective so- 68th Annual Meeting, Jan. 1989.
strengths. It is an economical means lution to reinforcing RCC. 10. Grzybowski, M., “Determination of
of producing military blast resistant Crack Arresting Properties of Fiber Rein-
structures. Conclusions ‘. forced Cementitious Composites,” Royal
Institute of Technology, Stockholm, Swe-
The concrete construction industry den, Chapter 12, June 1989.
Refractory is one that produces clever ap- 11. Grzybowski, Miroslaw, and Shah,
When concrete is exposed to high proaches to practical ways of using Surendra P., “Shrinkage Cracking of Fiber
temperatures and fire it sometimes concrete. The growth of the indus- Reinforced Concrete,” ACI Materials Jour-
explodes due to expansive moisture try through the years is a testimo- nal, V. 87, No. 2, Mar.-Apr. 1990, pp. 138-
148.
pressure trapped in the pore struc- nial of this ingenuity. Concrete is a 12. Soroushian, Parviz, and Lee, Cha
ture of the concrete. SFRC per- very versatile building material; Don, “Distribution and Orientation of Fi-
forms better than mesh reinforcing however, it would be used for many bers in Steel Fiber Reinforced Concrete,”
as the fibers constrain the expansive more applications today if it did not ACI Materials Journal, V. 87, No. 5, Sept.-
and explosive pressures. Oct. 1990, pp. 433-439.
crack. Steel fiber technology will 13. Bagate, M.; McCullogh, B.F.; Fowler,
advance many new solutions for the D.W.; and Muthu, M., “An Experimental
FR-RC combinations
cracking problem by making con- Thin-Bonded Concrete Overlay Pavement,”
In those congested areas where crete tougher and more ductile. Research Report 357-2F, Center for Trans-
higher tensile, shear, and flexural Most of today’s SFRC is well be- portation Research, University of Texas at
strengths are needed, steel fibers Austin, Nov. 1985.
yond the experimental stage of de-
add a composite action in combina- velopment. SFRC has been ac- Selected for reader interest by the editors.
tion with less conventional rebar cepted by owners, government
that is superior to reinforced con- agencies, architects, engineers, spe- ACI member Gary
crete. cifiers, contractors, and developers L. Vondran is Di-
for many practical applications. rector, Western
Repair of concrete and masonry Region, Novocon
These proven applications of SFRC
SFRC and SFRS are being used include: InteJnational Inc.
regularly for repairing concrete and 2685 Marine Way,
l Shotcrete
masonry structures. Steel fiber re- Mountain View, CA
l Precast concrete
inforcement adds the material in- 94043 (415)967-
l Slabs and floors 7812. With over 30
tegrity necessary to repair earth- l Pavements years in the concrete Industry, Gary
quake damage as well as deterio- l Seismic structures Vondran is active on ASTM CO9.03.04
rated concrete and masonry that has l Repairs committee on Fiber Reinforced Con-
failed due to long term environ- crete (FRC), and is a member of the
mental exposures. References Research Committee of the Transpor-
1. Schrader, E.K., “Fiber Reinforced tation Research Board. Besides serv-
Roller compacted concrete ing on ACI 544 FRC Committee, he
Concrete Pavements,” International Fibrous
Roller compacted concrete (RCC) is Concrete Institute (IFCI), First international also serves on ACI 201 Durability and
advancing as an economical means Symposium, Jan. 10, 1991. 506 Shotcrete Committees.

November 1991 4Y
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