Fiber reinforced building materials

Details Fiber reinforced building materials Fiber reinforced building materials

2000-12-13

2002-07-23

Marcantoni, Paul (Department: 1755)

Compositions: coating or plastic

Coating or plastic compositions

Inorganic settable ingredient containing

C106S644000, C106S724000

Reexamination Certificate

active

06423134

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to fiber reinforced building materials. In a particular aspect, the invention relates to methods for the production of building materials reinforced with synthetic fiber that, under agitation, progressively fibrillates, to produce building materials with enhanced performance properties. In another aspect of the present invention, there are provided articles prepared from the above-described fiber reinforced materials.
BACKGROUND OF THE INVENTION
Concrete has the largest production of all man made materials. Compared with other construction materials, it possesses many advantages including low cost, general availability of raw materials, adaptability and utilization under different environmental conditions. Therefore, concrete will most probably continue to be the dominant construction material in the foreseeable future. Unfortunately, plain concrete is also a brittle material with very low tensile strength and strain capacity, generally requiring reinforcement before it can be used extensively as a construction material.
The idea of using another material to reinforce a low tensile strength material is an age-old concept. For example, straw and horsehair have been used for thousands of years to improve the properties of clay bricks. Bentur, A., Mindess, S., “Fiber Reinforced Cemetitious Composites,” (Elsevier Applied Science, 1990), In more recent years, fibers have been incorporated into a wide range of engineering materials (including ceramics, plastics, cement, and gypsum products) to enhance the performance properties of the resulting composite. American Concrete Institute ACI 544.1R-96, “Fiber Reinforced Concrete,” 1996. Introduction of fibers into concrete results in post-elastic property changes that range from subtle to substantial, depending upon a number of factors, including matrix strength, fiber type, fiber modulus, fiber aspect ratio, fiber strength, fiber surface bonding characteristics, fiber content, fiber orientation, aggregate size effects, and the like. The enhanced properties include tensile strength, compressive strength, elastic modulus, crack resistance, crack control, durability, fatigue life, resistance to impact and abrasion, shrinkage, expansion, thermal characteristics, and fire resistance. Id.
Although fiber reinforcement is known to be more effective than conventional reinforcement in the control of local cracking, unlike reinforcing bars, it does not, in most cases, provide any increase in the load bearing capacity of concrete. Conventional reinforcing bars are strategically located in the structure to carry tensile stresses while fibers are distributed randomly in the concrete mixture. Fibers, therefore, are not used in design as a substitute for conventional reinforcement. Although not currently addressed by ACI Committee 318, fibers are sometimes used in structural applications with conventional reinforcement. American Concrete Institute, ACI 318 Building Code Requirements for Reinforced Concrete, 1995.
The practice of adding steel fibers to concrete to overcome its drawbacks was first introduced early in this century. Between 1920 and 1935 several patents pertaining to steel fiber reinforced concrete (SFRC) were granted. See, e.g., Kleinlagel, A., German Patent No. 388.959; Scailles, J. C., French Patent No. 514.186; Martin, G. C., U.S. Pat. No. 1,633,219; and Etherridge, H., U.S. Pat. No. 1,913,707. Use of glass fibers in concrete was first attempted in the USSR in the late 1950s. Biryukovich, K. L., and Yu, D. L., “Glass Fiber Reinforced Cement,” (translated by G. L. Cairns, CERA Translation, No.12, Civil Eng. Res. Assoc., London, 1965). Initial attempts at using synthetic fibers (nylon, polypropylene) were made in the 1960s. Monfore, G. E., “A review of Fiber Reinforced Portland Cement Paste, Mortar and Concrete,”
J. Res. Dev. Labs,
Vol. 10, No. 3, September 1968, pp. 36-42; Goldfein, S., “Plastic Fibrous Reinforcement for Portland Cement,” Technical Report No. 1757-TR, U.S. Army Research Development Laboratories, Fort Belvoir, October 1963, pp. 1-16.
When steel fibers first were used, only straight steel fibers were employed. The use of steel fibers resulted in improved characteristics for ductility and fracture toughness; flexural strength increases were also reported. For straight steel fibers, the primary factors that controlled the properties of the composite were fiber volume fraction and length/diameter, or aspect ratio of the fibers. The amount of fibers ranged from 90 to 120 kg/m
3
(1.1 to 1.5% by volume) of concrete. The aspect ratios were in the range of 60 to 100. The major problems encountered in the early stages were difficulty in mixing and workability. At higher volume fractions, fibers were found to ball up during the mixing process. This process, called balling, was found to occur frequently for longer fibers. This tends to affect the quality of concrete in place, especially for higher fiber volume fractions. Furthermore, there was always a reduction in workability of the concrete as a result of the addition of fibers.
The advent of deformed steel fibers in the late 1970's resulted in increased use of fiber reinforced concrete in the field. Ramakrishnan established that fibers with hooked ends can be used at much lower volume fractions than straight steel fibers, producing the same results in terms of product ductility and toughness. Ramakrishnan, V., Brandshaug, T., Coyle, W. V., and Schrader, E. K., “A Comparative Evaluation of Concrete Reinforced with Straight Steel Fibers and Deformed End Fibers Glued Together in Bundles,” ACI Journal, Vol. 77, No.3, May-June 1980, pp. 135-143. These fibers were glued together at the edges with water soluble glue such that, when added to the concrete, the fibers had a much lower (apparent) aspect ratio. During mixing, the fibers were separated and dispersed as individual fibers. The gluing and subsequent dispersal, in combination with a lower volume fraction of fibers, resulted in virtual elimination of balling. Later, a number of other fiber shapes such as crimped, paddled, and enlarged ends were also developed.
The ACI 544 Committee Report on Fiber Reinforced Concrete, published in 1996, reports that the first significant use of synthetic fibers in concrete was done in 1965, by the US Army Corps of Engineers Research and Development Section. American Concrete Institute ACI 544.1R-96, “Fiber Reinforced Concrete,” 1996. Synthetic monofilament fibers were used for construction of blast-resistant concrete structures. The fibers used were 13 to 25 mm long and had an aspect ratio of between 50 to 100, i.e. geometry not too different from the steel fibers being used in concrete at that time. With these fibers it was found that addition rates of up to 0.5% by volume of the concrete resulted in significant increases in ductility and impact resistance.
There was, however, very little commercial exploitation of fiber reinforcement technology and it was not until the 1980's that large scale development and use of synthetic fibers in concrete started to take place. This work was predominantly done with much lower denier fibers (i.e. small diameter fibers with high aspect ratios) at lower fiber addition rates. Morgan, D. R., and Rich, L., “High Volume Synthetic Fiber Reinforced Shotcrete,” The First International Conference on Synthetic Fiber Reinforced Concrete, Orlando, Fla., USA, Jan. 16, 1998. Most work was performed with collated, fibrillated polypropylene fibers at 0.1 to 0.2% by volume addition rates. At these lower fiber volume addition rates, the primary benefits of the fibers are for plastic shrinkage crack control and provision of green strength to extruded and certain green-cast, precast concrete products. Enhancement of ductility and impact resistance, and resistance to long term restrained drying shrinkage cracking is limited at such low fiber volume addition rates. It should be noted that even at these low fiber addition rates, the fiber count (number of fibers in a unit volume of matrix) and specific surface (surf

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