WO1993018912A1 - Composites renforces par un mat de fibres metalliques - Google Patents

Composites renforces par un mat de fibres metalliques Download PDF

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Publication number
WO1993018912A1
WO1993018912A1 PCT/US1993/001240 US9301240W WO9318912A1 WO 1993018912 A1 WO1993018912 A1 WO 1993018912A1 US 9301240 W US9301240 W US 9301240W WO 9318912 A1 WO9318912 A1 WO 9318912A1
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WO
WIPO (PCT)
Prior art keywords
fibers
structural member
mat
fiber
inch
Prior art date
Application number
PCT/US1993/001240
Other languages
English (en)
Inventor
Lloyd E. Hackman
David R. Lankard
Original Assignee
Hackman Lloyd E
Lankard David R
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hackman Lloyd E, Lankard David R filed Critical Hackman Lloyd E
Priority to JP5516546A priority Critical patent/JPH08502014A/ja
Publication of WO1993018912A1 publication Critical patent/WO1993018912A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/38—Fibrous materials; Whiskers
    • C04B14/48—Metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/012—Discrete reinforcing elements, e.g. fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
    • E04C5/02—Reinforcing elements of metal, e.g. with non-structural coatings of low bending resistance
    • E04C5/04—Mats

Definitions

  • the present invention relates to a cementitious memb reinforced by a non-woven mat of long steel fibers.
  • a metal fi reinforced structural member or composite wherein member comprises a non-woven, pre-formed mat of metal fibers which is infiltrated by and encased in a hardened cementitiou composition; the mat is characterized in that the fibers are to .060 inches in effective diameter, greater than 3 inches i length and have an aspect ratio (length/diameter) of about 40 1000 or they are continuous, and the density of the mat expre as a percentage of the fiber occupied volume to the total vol of the mat is about 1 to 10%.
  • the fiber mat-reinforced composite of this invention advantageous for several reasons.
  • the composites of the invention provide higher fiexural strength. Consequently, for comparable flexural strength, the volume of fibers in the composite can be reduced
  • the fiber mat reinforced composites of the invention exhibit higher energy absorption capacity than composites reinforced with discrete fibers, and their energy absorption efficiency (energy absorption capacity per unit volume of fibe is unexpectedly higher.
  • the superior performance of the mat reinforcement over the discrete fibers is related to the bondi of the mat fibers in the composite. With discrete fibers havi relatively short embedment length (e.g., 1 in.) fiber pullout the primary failure mode. For example, see U.S. Patent 3,986,885, Col.
  • Composites reinforced with the metal fiber mats in accordance with this invention represent a departure from the prior art.
  • the mode of failure in flexure is distinctly different.
  • multiple cracking occurs in the composites.
  • Ultimate failure occurs through fiber breakage in high tensile stress zones of one or more of the crack planes.
  • the energy absorption capacity of the mat reinforced composites reflects total energy required to initiate, enlarge, and propagate all the cracks and to break a portion of the fibers in one or more the cracks.
  • the yield strength of the steel is more fully utilized Contrary to what one skilled in the art might have expected ba on short fiber reinforced composites, energy absorption is not dictated by fiber pull out resistance.
  • a further advantage of reinforcing concrete composites in accordance with this invent as opposed to using individual fibers is that a known amount o fiber can be placed into the composite at a known cost.
  • Fig. 1 is a photograph of a steel fiber mat useful i accordance with the invention.
  • Fig. 2 is a perspective view of a reinforced concret structure in accordance with the present invention.
  • Fig. 3 is a cross-sectional view of fiber mat reinfo structural member in accordance with the invention.
  • Fig. 4 is a photograph of a cracked steel fiber reinforced comparative composite.
  • Fig. 5 is a photograph of a cracked long steel fiber composite in accordance with the invention.
  • non-woven as used herein with respect to metal fiber mats means that the fibers forming the mat are no systematically woven. The mat is held together by random entanglement of the fibers.
  • effective diameter is used herein as it i used in the art, namely, to mean the diameter of a circle the area of which is equal to the cross-sectional area of the ste fiber.
  • the fibers forming the reinforcing mat used in the present invention are greater than 3 inches long, preferably greater than 6 inches long and still more preferably about 7 12 inches long.
  • the fibers have an aspect ratio of about 400 1000.
  • Fiber mats useful in accordance with the invention commercially available from Ribtec, Ribbon Technology Corporation, Gahanna, Ohio under the tradename SIMCON.
  • One suc mat is shown in Fig. 1.
  • Metal fiber mats useful in the present invention can b prepared by the methods and apparatus described in U.S. Patents 4,813,472 and 4,930,565 to Ribbon Technology Corporation.
  • Thes patents disclose the production of metal filamentary materials ranging from a size less than one inch up to semicontinuous fibers.
  • To-prepare metal fiber mats the aforesaid methods may be used to prepare fibers.
  • the fibers are drawn from the molte metal using a melt overflow or melt extraction technique simila to that described in these patents and related patents.
  • Other methods may be used to prepare long fibers. For example, slit sheet processes and milling processes may be used to prepare lo fibers which in turn are air layed and compressed into mats.
  • T fibers are preferably about 7 to 12 inches long and more preferably about 9 inches long.
  • the fibers are blown into a ch where they are air layed on a conveyor and compressed into a ma
  • the density of the mat can be controlle to produce mats in the range of 1.5 to 6.0% density.
  • the optimum fiber length may vary with each particula application and the nature of the fiber, e.g., its diameter, steel composition and the method by which it is manufactured. length may be selected at which the force required to pull the fiber from the concrete exceeds the force required to form a n crack in the concrete, i.e., the minimum fiber length should b sufficient to prevent pullout.
  • the fibers are steel fibers such as carbon steel, stainless steel or manganese steel. Stainless steel fibers are preferred for refractory applications.
  • the fibers commonly range in effective diameter from about .004 to .060 i and more preferably form about .010 to .025 inch. Smaller diameter fibers are shown to provide higher energy absorption capacity in Examples 1 and 2 below.
  • the fibers typically are circular in cross-section but have thickness and width dimensions. For example in the examples they range from abou .02 to .05 in width and from about .005 to .015 inch in thickness.
  • a fiber having a circular cross section is also useful, but noncircular fibers are more commonly available an often less expensive. Depending upon the strength of the fib they may be corrugated.
  • the amount of fiber in the mat and the composite may range from about 1 to 10% by volume. In order to incorporate more than about 10% fiber into a composite, the mat must be compressed to an extent that it cannot readily be infiltrated with a cementitious mixture.
  • Typical composites in accordanc with the invention are prepared from mats which contain about to 6% by volume fiber.
  • the fibers may be randomly oriented in the composite oriented to maximize the strength of the composite in a selec direction.
  • the mat fibers may be oriented paral to the direction in which the structural member will encounte its principal tensile stress. In many applications, due to t geometry of the structural member, the fibers will assume so degree of orientation. For example, typically, the fibers a about 7 to 12 inches long.
  • fibers In making a panel 2 inches thick, fibers will be oriented generally perpendicular to the thick or Z direction of the panel and generally parallel to the X- plane of the panel. Within the X-Y planes, the fibers may as a parallel or a random alignment.
  • any cementitious composition which will infiltrate fiber mat may be used in the present invention including hydraulic and polymer cements.
  • Mortar and concrete composit are useful.
  • Representative examples of useful cements include Portland cement, calcium aluminate cement, magnesium phosphate cement, and other inorganic cements.
  • Useful aggregates may ran up to about 30 mesh (0.023 inch) so they are not strained from the composition as they impregnate the mat. Examples of aggregates include sand and small gravels.
  • Refractory concrete are used in making refractory shapes such as plunging bells, injection lances and ladle lip rings.
  • a superplasticizing agent may be added to the slurry o the cementitious material to better enable it to infiltrate the fibers and fill the mold.
  • a superplasticizing agent is not required but is preferred. Without the superplasticizer, more water must be added to the slurry to infiltrate the mat.
  • Superplasticizing agents are known and have been used in flowin concrete and water-reduced, high strength concrete. See for example "Superplasticized Concrete", ACI Journal, May, 1977, pp N6-N11 and “Flowing Concrete", Concrete Constr., Jan., 1979 (pp 25-27). The most common superplasticizers are sulfonated melamine formaldehyde and sulfonated naphthalene formaldehyde.
  • the superplasticizers used in the present invention are those which enable the aqueous cementitious slurry to fully infiltrat the packed fibers. Of those plasticizers that are commercially available. Mighty 150, a sulfonated naphthalene formaldehyde available from ICI is preferred.
  • Composites in accordance with the invention are useful in making a variety of structural members including panels, beams, columns, pavement slabs and refractory shapes.
  • a typica embodiment of a reinforced structure in accordance with the invention is shown in FIG. 2.
  • the embodiment there shown is of panel 10 provided with a non-woven metal fiber reinforcing mat which is completely embedded in a cementitious composition 13.
  • the face 14 of the panel 10 generally has fibers of the reinforcing layer incorporated therein and clearly visible. In this embodiment, the fibers are randomly oriented.
  • the ends 18 of fibers forming the mat 12 can be seen from the sides 20 an of panel 10.
  • the mat fiber reinforced panel may be incorporated in a sandwich constructi where a pair of mat fiber reinforced panels sandwich a layer large aggregate concrete or a layer of concrete reinforced by discrete metal fibers.
  • a structural member can be prepa by placing a fiber mat in a form and infiltrating that mat wi concrete slurry containing an aggregate which will not infilt the mat, e.g., a stone aggregate greater than 35 mesh. The l aggregate will be "screened" from the slurry and collect on t top surface of the mat. A second mat is placed in the form overlying the first and sandwiching the layer of large aggreg therebetween.
  • This second mat is infiltrated with a cement slurry not containing the larger aggregate resulting in a sla which the large area surfaces are mat reinforced and the core larger aggregate concrete.
  • metal fibers of th type referred to in the Romualdi and Lankard patents may be m with the concrete in an amount of 1 or 2% and poured between long fiber mat reinforced concrete layers to form a sandwich construction.
  • FIG. 3 illustrates, in a cross-sectional view, the sandwich structure 30 described above.
  • This structure compri two layers 22 and 24 which are formed from a hydraulic cement matrix with or without aggregate fillers and reinforced with woven elements 23 and 25 and which are separated from each ot by a layer of concrete 26.
  • the thickness of the two reinforc outer layers 22 and 24 can be the same or different and the relative thickness of the two outer layers versus the thickne of the inner mortar or concrete layer can be varied over a wi range depending upon the particular application for which the resulting structure is to be employed.
  • the inner layer of mo or concrete 26 can be reinforced, if desired, by means such a discrete metal fibers and the like to impart additional structural strength to the sandwich structures of the invention.
  • sandwich structures in accordance with the invention can be provided in which there ar a plurality of non-woven mat reinforced layers each of which is separated form its neighbor by a layer of concrete.
  • the reinforced structures of the invention can be prepared conveniently in a straightforward manner.
  • the reinforcing member such as that illustrated in FIG. 1 is placed in a tray or mold the internal surface of whic optionally may be previously treated with a conventional mold release agent.
  • An appropriate amount of cementitious compositi necessary to completely infiltrate and encapsulate the reinforcing member is then deposited on the latter.
  • Means such as vibration, ultrasonic stimulation, and the like, can be employed in order to ensure thorough permeation of the reinforcing member by the cementitious composition.
  • the upper surface of the mix can then be screeded if desired in order to ensure a planar surface of the desired finish. Thereafter, the impregnated reinforcing material is caused to cure by any conventional means.
  • Mat Two 304 stainless steel fiber mats were provided.
  • Mat is 2 inch thick x 18 inch wide x 38 inch long.
  • the weight of M A is 8.2 lb. These dimensions and the weight yield a fiber volume of 2.3 percent.
  • the individual fibers comprising this have a length of 8.81 inch, a width of around 0.04 inch,- and thickness of about 0.011 inch (average of measurements on 10 fibers randomly selected from the mat) .
  • Mat B measures 2-1/2 to 3 inch thick x 20 inch wide x 38-1/2 inch long. The mat weighs 24.2 lb. These dimensions a weight yield a fiber volume percent of 4.5. However, when compressed to a 2 inch thickness, the fiber volume is 5.7 percent.
  • the mats were individually placed in a plywood form a 2 inch x 20 inch x 40 inch long panel.
  • Mat B is compressed a final thickness of about 2 inch by the sides of the form.
  • a joints in the form are silicone sealed to contain the infiltrating slurry.
  • the fiber mats are infiltrated with a fine-grained refractory concrete slurry (Wahl Refractories SIFCA Compositio Approximately 180 lb. of the slurry was used at a water conten of 18.5 percent to fill the form.
  • the slurry wa cured for 24 hours at 85 to 90° F. Following this curing perio the panels were removed from the mold and given a further four days cure at 80 * F at 100 percent relative humidity in a fog ro Following the fog room curing period, each panel was cut into inch wide beams using a diamond saw. Specimens 2 inch x 4 inc 20 inch were then oven dried at 230 * F prior to testing the flexural strength properties.
  • a composite reinforced by discrete fibers was prepared using 1.0 inch long stainless steel fibers These specimens were prepared using the procedure described in U.S. Patent No. 4,366,255. The fiber content of the compariso composite is 14 volume percent. The composite specimens were cured and dried in the same manner as the composites prepared using the stainless steel fiber mats.
  • Load-deflection data were recorded during the flexura strength testing of the composites. To permit a comparison between the composites evaluated here, a total area under the load-deflection curve to a maximum deflection of 0.35 inch was calculated. These results are also presented in Table 1.
  • a comparison of the areas under the load-deflection curves between the comparison composite at 14 volume percent fiber and Mat B at 5.7 volume percent fiber establish the superior energy absorbing capacity provided by the long fiber mode of reinforcement.
  • the superior performance of the mat reinforcement over the discrete fibers is related to the bondi of the long mat fibers in the composite.
  • the relatively short embedded length of the fibers results in fiber pullout as the primary failu mode.
  • the length of the individual fibers is about 9-1/2 i Fiber width varied from 0.022 inch to 0.039 inch with thickne varying from 0.006 inch to 0.011 inch.
  • Each of fiber mats C-F was enclosed in a 20 inch x 4 inch x 2 inch wooden mold with the open face (filling port) b the 2 inch x 40 inch dimension.
  • a calcium aluminate cement-b slurry (SIFCA Slurry manufactured by Wahl Refractories, Fremo Ohio) was used to infiltrate these panels. Once infiltration achieved, the panels were cured one day in the mold and then placed in a 74 * F/100%RH environment until two individual spec (roughly 2 inch x 4 inch x 20 inch) were sawcut from each pan
  • Load-deflection data were recorded during the flexur strength testing of the composites. To permit a comparison between the composites evaluated here, a total area under the load-deflection curve to a maximum deflection of 0.35 inch, w calculated.
  • 1.0 inch fibers is principally fiber pullout.
  • the average ultimate flexural strength of the compar composite (14 volume percent 1 inch fibers) is 6440 psi.
  • Manganese carbon steel Mats E and F at fiber loadings of 3.3 3.6 volume percent respectively provided an ultimate flexural strength of 4800 psi in the composite (roughly 75 percent tha the comparison composite).
  • Manganese steel fiber Mat D at a loading of 1.7 volume percent had an average ultimate flexura strength of 3200 psi or 50 percent that of the comparison composite.
  • Manganese steel Mat C at a fiber loading of 1.2 v percent had an average ultimate flexural strength of 1950 psi around 30 percent that of the comparison composite.
  • Mat D a reinforcement level only 12 percent that of the Comparison provided an ultimate flexural strength of 50 percent that of Comparison.
  • Mat D provided a fiber loading roughly half that o Mat E, yet provided an equivalent energy absorption capacity in the composite.
  • the only intended difference in the two mats is smaller fiber diameter in Mat D (0.013 inch) relative to Mat E (0.021 inch).
  • the influence of fiber diameter is also seen in the comparison of the energy absorption capacity of the composites prepared with Mat E and Mat F.
  • the fiber loading is roug equivalent (3.3 and 3.6 volume percent) but the energy absorpti capacity in the finer diameter steel Mat F is 35 percent greate than that in the composite containing the coarser fiber Mat E.
  • the ultimate flexural strength of these two mat reinforced composites is equivalent (around 4800 psi).

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention se rapporte à un élément ou composite structurel renforcé par des fibres métalliques (10). L'élément comprend un mat préformé, non tissé de fibres métalliques (12) dans lequel on a fait pénétrer une composition de cémentite durcie (13) et qui est enrobée de celle-ci; le mat (12) se caractérise en ce que les fibres ont un diamètre effectif compris entre 0,004 et 0,060 pouces, une longueur supérieure à 3 pouces et un rapport d'élancement (longueur/diamètre) d'environ 400 à 1000, ou bien elles sont continues, et la densité du mat exprimée en pourcentage de volume occupé par les fibres par rapport au volume total du mat est d'environ 1 à 10 %.
PCT/US1993/001240 1992-03-16 1993-02-11 Composites renforces par un mat de fibres metalliques WO1993018912A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP5516546A JPH08502014A (ja) 1992-03-16 1993-02-11 金属繊維マット強化複合材料

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US85164792A 1992-03-16 1992-03-16
US07/851,647 1992-03-16

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WO1993018912A1 true WO1993018912A1 (fr) 1993-09-30

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JP (1) JPH08502014A (fr)
AU (1) AU3664193A (fr)
IL (1) IL104317A (fr)
WO (1) WO1993018912A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0683714A1 (fr) * 1992-11-17 1995-11-29 Ribbon Technology Corporation Procede de fabrication d'un element porteur en ciment arme
FR2762028A1 (fr) * 1997-04-14 1998-10-16 Lafarge Sa Piece de construction renforcee et son procede de fabrication
ES2142701A1 (es) * 1996-06-20 2000-04-16 Espanola Explosivos Hormigon reforzado con alta resistencia a la penetracion y polvorin movible fabricado con dicho material.
US6074752A (en) * 1997-01-17 2000-06-13 N.V. Bekaert S.A. Metal fibre agglomerate and process for manufacturing the same
EP2169135A2 (fr) * 2008-09-29 2010-03-31 Holding Jousselin SAS Procédé de fabrication d'un mur isolé à coffrage intégré comprenant deux peaux béton et des connecteurs, incluant une étape de vibration ultrasonique, ainsi que l'installation correspondante et les connecteurs correspondants
US11768193B2 (en) 2019-12-20 2023-09-26 The Research Foundation For The State University Of New York System and method for characterizing the equibiaxial compressive strength of 2D woven composites

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11225793B2 (en) * 2018-04-27 2022-01-18 United States Gypsum Company Fly ash-free coating formulation for fibrous mat tile backerboard
CN116086533A (zh) * 2023-01-10 2023-05-09 广州大学 自修复功能的混凝土结构健康监测系统及方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4617219A (en) * 1984-12-24 1986-10-14 Morris Schupack Three dimensionally reinforced fabric concrete

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4617219A (en) * 1984-12-24 1986-10-14 Morris Schupack Three dimensionally reinforced fabric concrete

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0683714A1 (fr) * 1992-11-17 1995-11-29 Ribbon Technology Corporation Procede de fabrication d'un element porteur en ciment arme
EP0683714A4 (fr) * 1992-11-17 1997-06-04 Ribbon Technology Corp Procede de fabrication d'un element porteur en ciment arme.
ES2142701A1 (es) * 1996-06-20 2000-04-16 Espanola Explosivos Hormigon reforzado con alta resistencia a la penetracion y polvorin movible fabricado con dicho material.
US6074752A (en) * 1997-01-17 2000-06-13 N.V. Bekaert S.A. Metal fibre agglomerate and process for manufacturing the same
FR2762028A1 (fr) * 1997-04-14 1998-10-16 Lafarge Sa Piece de construction renforcee et son procede de fabrication
EP2169135A2 (fr) * 2008-09-29 2010-03-31 Holding Jousselin SAS Procédé de fabrication d'un mur isolé à coffrage intégré comprenant deux peaux béton et des connecteurs, incluant une étape de vibration ultrasonique, ainsi que l'installation correspondante et les connecteurs correspondants
FR2936538A1 (fr) * 2008-09-29 2010-04-02 Holding Jousselin Procede de fabrication d'un mur isole a coffrage integre comprenant deux peaux beton et des connecteurs, incluant une etape de vibration ultrasonique, installation et connecteurs correspondants
EP2169135A3 (fr) * 2008-09-29 2010-09-29 Holding Jousselin SAS Procédé de fabrication d'un mur isolé à coffrage intégré comprenant deux peaux béton et des connecteurs, incluant une étape de vibration ultrasonique, ainsi que l'installation correspondante et les connecteurs correspondants
US11768193B2 (en) 2019-12-20 2023-09-26 The Research Foundation For The State University Of New York System and method for characterizing the equibiaxial compressive strength of 2D woven composites

Also Published As

Publication number Publication date
IL104317A (en) 1995-10-31
AU3664193A (en) 1993-10-21
IL104317A0 (en) 1993-05-13
JPH08502014A (ja) 1996-03-05

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