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Highly durable precast special concrete reinforced with non metallic rebars

Objective



Objectives and content: At present, construction methods are being more and more diversified, and precast concrete applications are increasing day by day, especially in countries where concrete manufacturing technologies are not developed. However, in the case of plane concrete elements, geometry of these pieces oblige to the maintenance of a low cover depth, which do not confer enough protection to the steel reinforcement when they are exposed to aggressive environments. In some cases, these elements are exposed into electric fields (railway crossings), creating erratic currents, which seriously damage metallic rebars. For this reason, a market survey by constructors has shown that there is a strong industrial need for the development of new types of precast plane reinforced elements, for architectural and structural purposes, which could be reliably used in aggressive environments or when electrical isolation is required.

The industrial objectives of these projects are:
- Improving durability of precast plane reinforced elements in 70% by the use of non-metallic rebars;
- Development new technologies for precast concrete, more competitive, towards U.S.A. and Japan;
- Diversification of construction solutions, through the introduction of new constructive precast systems;
- Reduction of thickness and weights of the elements in 15 % with the same or improved properties;
- Offering new competitive products being able to be reliably worldwide applied in all climate conditions;
- Avoiding of maintenance and repair costs (reduction to 0) for non-metallic reinforcement;
- Design and development of a new reinforcement with non-metallic rebars for cement and polymer concrete;
- Development design procedure for both cement and polymer concrete elements reinforced with plastic bars. The primary aim of the project is the development of new, reliable and cost effective high added value precast concrete elements, integrating traditional materials (such as cement concrete) with new material systems (fibre plastic reinforced bars and polymer concrete) to produce structural materials with enhanced performance (better corrosion and weathering conditions).

The technical approach comprises:
- A study on the type and reliability of constituents;
- The characterisation and tests on concrete and fibre reinforced plastic rebars (FRPB);
- Mechanical, long and accelerated behaviour of the new cement and polymer concrete reinforced with FRPB;
- Design guides of the reinforced precast polymer and cement concrete architectural and structural elements;
- Technical-economical analysis for industrial and commercial application of these elements.

The achievements of the project will be:
- New technologies for manufacturing, design and placing of precast cement and polymer concrete;
- Design and calculation E.U. guidelines for precast cement and polymer concrete with non-metallic rebars;
- Performance criteria and adjusted procedures for durability and mechanical testing. The partnership is highly complementary and multidisciplinary. MAPREL (constructor), Italcementi (cement and concrete precaster and producer), ULMA (polymer concrete architectural elements precaster), GMUNDNER (polymer concrete structural elements precaster), EUROCRETE (manufacture and supply the non-metallic rebars), CARL BRO (engineering), BAUSTIFFINSTITUT, INEGI and LABEIN (research centres). Subsidiarity, European social and economic cohesion are also envisaged (T.R.A.).

Main expected benefits are:
- Market expansion for new products (in precast concrete) breaking into new markets inside and outside E.U;
- The reduction of construction and repairing costs;
- The increasing of products service life in 70%. BE97-5094

Coordinator

INSTITUTE OF MECHANICAL ENGINEERING AND INDUSTRIAL MANGEMENT
Address
Rua Do Barroco, 174/214
4465-591 Sao Mamede De Infesta
Portugal

Participants (10)

CARL BRO A/S
Denmark
Address
14,Granskoven 8
2600 Glostrup
CTG S.P.A. - CENTRO TECNICO DI GRUPPO
Italy
Address
124,Via G. Camozzi 124
24121 Bergamo
Gmundner Fertigstelle GesmbH & Co. KG
Austria
Address
1,Unterhalham Strasse
4694 Ohlsdorf
Italcalcestruzzi
Italy
Address
124,Via G. Camozzi
24121 Bergamo
Italcementi SpA
Italy
Address
Via Camozzi 124
24100 Bergamo
Laboratorio de Ensayos e Investigaciones Industriales
Spain
Address
16,Cuesta De Olabeaga
48013 Bilbao
MAPREL - Empresa de Pavimentos e Materiais Pre-Esforcados Lda
Portugal
Address
51,Rua De Sabrosa
4300 Porto
TECHNICAL UNIVERSITY OF MUNICH
Germany
Address
7,Baumbachstrasse 7
81245 Muenchen
Trend 2000 Ltd.
United Kingdom
Address
Pointon Fen
NG34 0LF Sleaford
Ulma Forja S. Coop
Spain
Address
3,Bè Zubillaga
20560 Oñate