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Livrables
A design guide (with recommendations) and calculation procedures was performed. It contains a number of results and methods for designing beams and slabs of frp-reinforced polymer concrete and mortars. These results have been compared with experimental results and there is an interesting agreement between both. The method is established in the form of a spreadsheet.The established design guide is similar to traditional calculations in ordinary concrete under bending loads.
Pultruded profiles without surface control (smooth surface) are available to the market. They are composed of glass fibre and polyester resin. It aims at reinforcing concrete structures. In particular it aims at reinforcing polymer concrete beams or slabs, due to a good compatibility between both matrices.
An analytical procedure was performed according to concrete codes. Sometimes a more powerful method is necessary for calculation of displacements, deformations and stresses. We developed a new finite element code that performs the non-linear analysis of frp-reinforced concrete structures. It accounts for geometric and material non-linearities. It is based on a layered formulation and can be used for beams, plates or shells.
A new panel with cement concrete and frp rebars was developed by MAPREL. It is experimented in a big new development on housing in Portugal. The only application possible, for the moment, is the manufacturing of façade panels, which need no shaping of the rebars; they can be made with a square mesh of FRP rebars by INEGI. So, a test will be carried out in an industrial building, that is being executed in the present. These façade panels are already made and will be placed in June/2002.
The experimental evaluation of the tensile properties of polymer concretes also at low and high temperatures in a temperature chamber can be performed with test specimens cast in the required shape in the appropriate forms. Tests with standard clamping fixtures do not give the correct results as on the tensile stresses compressive stresses are superimposed. The method of gluing the specimens to steel plates as used often with cement concrete is not successful due to the high strength of the polymer concrete.
Creep testing is one of the most relevant test to be performed on polymer concretes and mortars, due to the viscoelastic nature of such materials. However, it is neither practical nor economical to use a standard testing machine during one or two years just to test one specimen. Therefore new creep testing machines were developed by LABEIN and INEGI for compressive creep testing and flexural creep testing, respectively.
The compression creep machine is designed in order to maintain a low variability of the load applied, which usually occurs in the polymer concretes due to its high deformability. This aspect permits to eliminate the continuous reposition of testing loads. Such machines can be inserted in climatic chambers, due to their small size. They can be used either by academics or companies due to their simplicity in use. Moreover they can be used for other materials, with small changes.
Reinforcing polymer concrete structures with steel reinforcement is not new. In this project we developed an hybrid reinforcement that combines steel reinforcement with frp reinforcement. It provides a lighter yet more resisting reinforcement at a very reasonable cost.
The feasibility of the production of new polymer concretes is demonstrated, with thermoset resins such as polyester resin, and natural aggregates, such as silica sand. The new polymer concretes will enable industrial partners to continue their commercial strategy in national and international terms.
There are different types of resins. For all the required values and for economical reasons and due to an evaluation GMUNDNER uses an orthophtalic polyester resin and a special additive to avoid high shrinkage of the polymer concrete. The mix design of the concrete and the content of resins will be tested in this project. The calculated content of resins in the compound shall be about 10,0% and as a variation about 12,0% of the weight. GMUNDNER got the offer of the resin suppliers to make tests with a new developed hybrid resin (a combination of polyurethane typed and polyester typed resins).
Tests of polymer concrete with hybrid-resins in June 2000
First tests have shown that the compressive strength increases up to 155MPa standard and 167MPa with postcuring after casting the specimen and the tests have also shown that the content of resins using a hybrid-resin (GF specification) in polymer concrete (pc) can be reduced to around 8,5% up to 9,5% instead of 10,5% up to 12,5% with polyester resins. The design guide and calculation procedures will enable industrial partners to optimise the material consumption.
This is a very light panel manufactured by ULMA that incorporates polymer mortar reinforced with frp rebar. It provides an adequate façade panel that is resistant to mechanical and environment actions, with sufficient economic conditions to be accepted by the general public. Colours come naturally from the mould and can be chosen by the client.
The new FRP designs are developed specifically for the polymer concrete environment and are about one third the cost of conventional non-ferrous reinforcement for cement concrete. The advances have been made in bonding technology and raw materials selection due to the low alkali environment and inherent bond strength of polymer concrete. The reinforcement can be utilised within polymer concrete to enable thinner sections and/or lighterweight units to be produced. Some first cost savings over galvanised bars have been found but 15% weight savings are realistic and reduce subsequent transport and installation costs accordingly.
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