ACI 549 5R-2016 Report on Spray-Up and Continuous Strand Glass Fiber-Reinforced Concrete (GFRC).pdf

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1、Report on Spray-Up and Continuous Strand Glass Fiber-Reinforced Concrete (GFRC)Reported by ACI Committee 549ACI 549.5R-16First PrintingMarch 2016ISBN: 978-1-942727-73-6Report on Spray-Up and Continuous Strand Glass Fiber-Reinforced Concrete (GFRC)Copyright by the American Concrete Institute, Farming

2、ton Hills, MI. All rights reserved. This material may not be reproduced or copied, in whole or part, in any printed, mechanical, electronic, film, or other distribution and storage media, without the written consent of ACI.The technical committees responsible for ACI committee reports and standards

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4、ment of ACI documents are requested to contact ACI via the errata website at http:/concrete.org/Publications/DocumentErrata.aspx. Proper use of this document includes periodically checking for errata for the most up-to-date revisions.ACI committee documents are intended for the use of individuals wh

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6、use of this information.All information in this publication is provided “as is” without warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose or non-infringement.ACI and its members disclaim liabilit

7、y for damages of any kind, including any special, indirect, incidental, or consequential damages, including without limitation, lost revenues or lost profits, which may result from the use of this publication.It is the responsibility of the user of this document to establish health and safety practi

8、ces appropriate to the specific circumstances involved with its use. ACI does not make any representations with regard to health and safety issues and the use of this document. The user must determine the applicability of all regulatory limitations before applying the document and must comply with a

9、ll applicable laws and regulations, including but not limited to, United States Occupational Safety and Health Administration (OSHA) health and safety standards.Participation by governmental representatives in the work of the American Concrete Institute and in the development of Institute standards

10、does not constitute governmental endorsement of ACI or the standards that it develops.Order information: ACI documents are available in print, by download, on CD-ROM, through electronic subscription, or reprint and may be obtained by contacting ACI.Most ACI standards and committee reports are gather

11、ed together in the annually revised ACI Manual of Concrete Practice (MCP).American Concrete Institute38800 Country Club DriveFarmington Hills, MI 48331Phone: +1.248.848.3700Fax: +1.248.848.3701www.concrete.orgGlass fiber-reinforced concrete (GFRC) is a popular construction material used to manufactu

12、re precast concrete products in archi-tectural and civil engineering applications. GFRC products have desirable aesthetics and physical properties, including durability, strength, toughness, moisture resistance, dimensional stability, and fire resistance. This report summarizes the processes, prop-e

13、rties, and applications of GFRC made by the spray-up process, and processes that use continuous strands and woven, knitted, or bonded textiles.Keywords: alkali-resistant glass fiber; architectural panels; cement boards; composites; concrete panels; ductility; durability; fiber-reinforced concrete; f

14、ilament winding; formwork; glass fiber-reinforced concrete; glass-reinforced concrete; mesh reinforcement; permanent formwork; premix; precast concrete; spray-up process; textile-reinforced concrete; toughness.CONTENTSCHAPTER 1INTRODUCTION AND SCOPE, p. 21.1Introduction, p. 21.2History, p. 21.3Scope

15、, p. 3CHAPTER 2NOTATION AND DEFINITIONS, p. 32.1Notation, p. 32.2Definitions, p. 3CHAPTER 3APPLICATIONS, p. 43.1 Glass fiber-reinforced concrete architectural clad-ding, p. 43.2Textile-reinforced concrete, p. 93.3 Glass fiber-reinforced concrete filament-wound poles, p. 103.4 GFRC permanent formwork

16、, p. 123.5 Flat and profiled panel products, p. 14CHAPTER 4FABRICATION, p. 154.1Spray-up process, p. 154.2Textile-reinforced concrete, p. 174.3 Filament winding, p. 17CHAPTER 5PROPERTIES, p. 185.1 General properties, p. 185.2Fire properties, p. 205.3Long-term properties, p. 205.4Freezing-and-thawing

17、 resistance, p. 21John Jones*, ChairACI 549.5R-16Report on Spray-up and Continuous Strand Glass Fiber-Reinforced Concrete (GFRC)Reported by ACI Committee 549Corina-Maria AldeaP. N. BalaguruHiram Price Ball Jr.Nemkumar BanthiaGordon B. BatsonNeeraj J. BuchCesar ChanJames I. DanielAntonio De LucaAshis

18、h DubeyGarth J. FallisGraham T. GilbertAntonio J. GuerraJames R. McConaghyBarzin MobasherAntoine E. NaamanAntonio NanniJames E. PattersonAlva PeledMartin PullanD. V. ReddyLarry RowlandPaul T. SarnstromScott ShaferSurendra P. ShahYixin ShaoRobert C. ZellersConsulting MembersLloyd E. HackmanPaul Nedwe

19、llP. ParamasivamParviz SoroushianRonald F. Zollo*Chair of subcommittee responsible for preparing this report.Members of subcommittee that prepared this report.The committee thanks P. H. Mokhiber for his contributions.ACI Committee Reports, Guides, and Commentaries are intended for guidance in planni

20、ng, designing, executing, and inspecting construction. This document is intended for the use of individuals who are competent to evaluate the significance and limitations of its content and recommendations and who will accept responsibility for the application of the material it contains. The Americ

21、an Concrete Institute disclaims any and all responsibility for the stated principles. The Institute shall not be liable for any loss or damage arising therefrom.Reference to this document shall not be made in contract documents. If items found in this document are desired by the Architect/Engineer t

22、o be a part of the contract documents, they shall be restated in mandatory language for incorporation by the Architect/Engineer.ACI 549.5R-16 was adopted and published March 2016.Copyright 2016, American Concrete Institute.All rights reserved including rights of reproduction and use in any form or b

23、y any means, including the making of copies by any photo process, or by electronic or mechanical device, printed, written, or oral, or recording for sound or visual reproduc-tion or for use in any knowledge or retrieval system or device, unless permission in writing is obtained from the copyright pr

24、oprietors.15.5Creep, p. 215.6S ustainability, p. 21CHAPTER 6DESIGN PROCEDURES, p. 226.1 U.S. glass fiber-reinforced concrete design practice, p. 226.2 European glass-reinforced concrete design practice, p. 236.3 Recently proposed design procedure, p. 23CHAPTER 7REFERENCES, p. 26Authored documents, p

25、. 26CHAPTER 1INTRODUCTION AND SCOPE1.1IntroductionGlass fiber-reinforced concrete (GFRC) is a composite of alkali-resistant (AR) glass fibers embedded in a cementi-tious mixture, which could be a paste, mortar, or concrete, possibly with additives and admixtures added for improved processability, pr

26、operties, or both. The fibers could be short individual fibers or monofilaments; bundles of fibers, which are often referred to as chopped strands; continuous strands or roving, or textiles (Fig. 1.1). Textiles are also synony-mously called scrims, fabrics, or meshes.Only AR glass fibers should be u

27、sed in GFRC composites, to which this report is confined. There are four processes used to manufacture GFRC:1) Premix2) Spray-up, which usually contains a minimum of 4 percent chopped AR glass fiber roving strands by mass of the composite traditionally referred to as GFRC3) Textile-reinforced concre

28、te (TRC), which uses contin-uous structured AR glass fibers in woven (typically leno weave), knitted, and bonded constructions such as fabrics, scrims, or meshes4) Continuous strands in oriented patterns such as filament windingThis report covers Items 2 through 4 and is a companion to ACI 549.3R, w

29、hich covers Item 1.GFRC is not just a single material, but rather a variety of materials with different properties and performance charac-teristics. Because GFRC in any of its forms does not contain steel reinforcing bars, there is no need of extra concrete cover to protect steel against corrosion.

30、This allows it to be produced in thin sections, typically 0.5 to 1.0 in. (13 to 25 mm), which makes GFRC products much lighter in weight compared to conventional concrete products, which are usually 2 in. (50 mm) or thicker, although both are similar in density.GFRC products have several significant

31、 advantages over conventional precast concrete products. They are light-weight, easy to handle and install, and have high toughness. Being lightweight offers cost-effective concrete-based alter-natives in applications where the heavy weight of conven-tional precast concrete would make it unsuitable.

32、Research on GFRC composites began in the 1960s and has been in successful commercial use for over 40 years. This is proof that, if designed and manufactured to accepted, recom-mended practices, GFRC has a durability and longevity to be an acceptable building material. Its properties have been thorou

33、ghly researched, probably as much as, if not more than, any other material. Further research and development of new applications and mass production processes will move GFRC into the next phase of large-scale use.1.2HistoryMuch of the original research performed on glass fiber-reinforced cement past

34、e took place in the early 1960s. This work used conventional borosilicate glass fibers (E-glass) and soda-lime-silica glass fibers (A-glass). The chemical compositions, densities, and mechanical properties of E- and A-glass are listed in Tables 1.2a and 1.2b. Glass compositions of E- and A-glass wer

35、e found to lose strength quickly because of the high alkalinity (pH 12.5) of port-land cement-based materials. Consequently, early A- and E-glass cementitious composites were unsuitable for long-term use (Larner et al. 1976). Some E-glass products have been developed with alkali-resistant (AR) coati

36、ngs, but Fig. 1.1Alkali-resistant glass fiber roving, chopped strands, and textile (bonded scrim).Table 1.2aChemical composition of selected glasses, percent of total by massComponent A-glass E-glass AR glass #1 AR glass #2SiO273.0 54.0 62.0 61.0Na2O 13.0 14.8 15.0CaO 8.0 22.0 MgO 4.0 0.5 K2O 0.5 0.

37、8 2.0Al2O31.0 15.0 0.8 Fe2O37.0 0.3 B2O3 7.0 ZrO2 16.7 17.5TiO2 1.0 Li2O 1.0American Concrete Institute Copyrighted Material www.concrete.org2 REPORT ON SPRAY-UP AND CONTINUOUS STRAND GLASS FIBER-REINFORCED CONCRETE (ACI 549.5R-16)these should be viewed with caution because glass filaments are very

38、fine, with typical diameters of approximately 56 105in. (13 microns). If the coating is degraded physi-cally or chemically, the exposed reinforcing filaments will be quickly degraded away. Also, the ends of the fibers in chopped strands are exposed, and alkalis can wick along the fibers and attack t

39、hem.Continued research resulted in the development of AR glass fiber, which improved the long-term durability of glass fiber-reinforced concrete (GFRC). The alkali resistance of AR glass fiber derives solely from its glass composition and is not dependent on surface coatings.The specifications for A

40、R glass fiber are given in ASTM C1666/C1666M. Alkali resistance significantly increases with increasing zirconia contents up to 16 percent, but only increases slightly with a further increase in zirconia content (Majumdar and Laws 1991; Bentur et al. 1985).Chemical compositions and properties of com

41、mercially available AR glass fiber are provided in Tables 1.2a and 1.2b, respectively. Since the introduction of GFRC in 1970, a wide range of applications in the construction industry have been established. Although much of the research and development was completed in the 1970s and 1980s, more rec

42、ent work on technology, material, and application devel-opments was presented at the biennial congresses organized by the Glassfibre Reinforced Concrete Association (1998, 2001, 2003, 2005, 2008, 2011, 2015).1.3ScopeThis report provides practical information about alkali-resistant (AR) glass fiber-r

43、einforced concrete (GFRC), including a comprehensive compilation of international data and references oriented toward increasing the awareness of producers, engineers, architects, and end users about GFRC technology and its use in a variety of applications. The funda-mental principles of materials,

44、mixture proportions, proper-ties, manufacturing processes, and applications of GFRC are reviewed in this report. This report offers an overview of current design practices with references to design guides. The various industrial applications of GFRC include archi-tectural panels, permanent formwork,

45、 utility poles, textile-reinforced concrete, and standard panel products.CHAPTER 2NOTATION AND DEFINITIONS2.1NotationFd= ultimate design load, or factored loadFk= service loadfu = assumed (aged) modulus of rupture or ultimate flexural strength, psi (MPa)fur= average 28-day modulus of rupture strengt

46、h of 20 consecutive tests (each test being the average of six individual test coupons), psi (MPa)fyr= average 28-day proportional elastic limit strength of 20 consecutive tests (each test being the average of six individual test coupons), psi (MPa)k1, k2= reduction factorst = students ta statistical

47、 constant to allow for the proportion of tests that may fall below fu; the value is 2.539 for the recommended 20 testsR = resistanceS = actionss = shape factorVf= volume fraction of fibersVu= coefficient of variation of the modulus of rupture test strengthsVy= coefficient of variation of the proport

48、ional elastic limit test strengths = strength reduction factor = ratio of compressive and tensile modulusf= load factortv= factor to account for variations in thickness of glass fiber-reinforced concreteb= factor to allow for difference in bending behavior between test coupon and full-size sectionc=

49、 factor to account for mode of collapse and conse-quence of failurem= partial safety factor2.2Definitionsacrylic copolymeracrylic thermoplastic copolymer is a resinous substance made by reacting acrylic monomers together; the type of copolymer used in concrete and glass fiber-reinforced concrete is an emulsion of submicron-size polymer particles dispersed in water.alkali-resistant glass fiberglass fiber using at least 16 percent zirconia by mass.characteristic strengthvalue of a strength;