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September 2012
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Forword
This guideline was written from a Task Group of ERMCO Ecotec supported from European
experts from the ready mixed concrete industry and the fibre industry.
It took long to come to this final draft, with many long breaks, but the last years were not
easy for business and also not for concrete business. But this document is finally a good
and useful report (to say it with the words of Tom Harrison, Chairman of ERMCO Ecotec).
I want to thank all our Task Group members for your work and support.
Finally I also want to thank Tom Harrison, who supported us with his huge knowledge and
experience and who helped us to finalise work. I also want to thank John Gibbs, Secretary of
ERMCO Ecotec, who always was a very critical reader of our working papers and pushed us
to be more precise and specific.
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Contents:
1
INTRODUCTION ....................................................................................................................................... 5
SCOPE .......................................................................................................................................................... 5
CONSTITUENTS ...................................................................................................................................... 10
5.1
GENERAL ............................................................................................................................................ 10
5.2
FIBRES ................................................................................................................................................ 10
5.2.1
CE marking: .................................................................................................................................. 10
5.2.2
Steel or Macro-polymer fibres ...................................................................................................... 13
5.2.3
Micro-polymer fibres..................................................................................................................... 17
5.2.4
Coatings of fibres .......................................................................................................................... 18
CONSISTENCE ..................................................................................................................................... 18
PUMPABILITY...................................................................................................................................... 19
AIR CONTENT ...................................................................................................................................... 20
BLEEDING ........................................................................................................................................... 20
PLASTIC SHRINKAGE AND PLASTIC CRACKING .................................................................................... 20
GENERAL ............................................................................................................................................ 20
COMPRESSIVE STRENGTH.................................................................................................................... 22
POST-CRACK TENSILE STRENGTH ........................................................................................................ 22
FIRE RESISTANCE ................................................................................................................................ 23
IMPACT RESISTANCE ........................................................................................................................... 23
SHEAR RESISTANCE ............................................................................................................................ 24
DURABILITY ....................................................................................................................................... 24
CREEP ................................................................................................................................................. 24
SPECIFICATION ..................................................................................................................................... 25
9.1
9.2
9.3
10
CONFORMITY ......................................................................................................................................... 29
10.1
10.2
10.3
11
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13
RECOMMENDATIONS .......................................................................................................................... 36
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1 Introduction
Fibre concrete is an established product now being widely used for applications such as
industrial floors, roads, pavements, tunnelling, composite constructions, walls, precast
segments and more. Recognition of the benefits of adding fibres into concrete is leading to
an extension of the possible areas of application in structural and civil engineering.
This document is not primarily intended as another general guidance document on the
properties of fibre concrete. Rather, ERMCOs intention is to clarify what is required from the
ready-mixed concrete industry when producing such concrete.
It proposes methods of
specification and conformity procedures for fibre concrete in the same way that other
concrete and concrete properties are handled in EN206 Concrete.
Some European countries have issued guidance and/or regulate or standardize fibre
concrete with national guidelines. These national standards increasingly specify a required
performance of the composite material.
The fib Model Code comprising the design recommendation for fibre concrete
(XV)
, which was
issued in a draft version in 2010, describes performance classes for fibre concrete.
The European Committee for Standardisation (CEN) has recognised the increasing
importance of fibre concrete, and harmonised product standards have been issued for steel
fibres, macro-polymer fibres and micro-polymer fibres. The draft of the revised European
concrete standard, prEN206, includes requirements for fibre concrete and therefore this
Guideline should give important support for concrete producers and specifiers with little
experience with fibre concrete.
Note: In the text, numbers in superscript refer to numbered references.
2 Scope
This document is not intended to replace national Guidance Documents on the properties of
fibre concrete, and it deals with fresh and hardened properties only briefly; rather, it is
intended as guidance for specifiers and ready-mixed concrete producers. In the light of the
inclusion of fibres in prEN206 (2012), it focuses on methods of specification and conformity,
on the practicalities of production (including health and safety aspects), and on progress in
standardization. The annex gives some information on methods of testing aspects of tensile
strength.
Sprayed concrete is not covered because standards already exist for such concrete, and
because the European Federation for Specialist Construction Chemicals and Concrete
Systems (EFNARC) has written a widely accepted document (xvi) on the subject.
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The document contains terms and definitions that are used in existing publications
(referenced documents). It covers the use of steel and polymer fibres, but not carbon or
glass fibres as these types of fibres are not standardized at the European level and, at
present, confined to niche market uses.
Emphasis is given to the production of fibre concrete, which requires special attention from
ready-mixed concrete producers and the affects on concrete performance.
Finally, a number of recommendations for best practice of fibre concrete are offered.
3.1
EN 14889-1:
conformity.
This Standard defines requirements for steel fibres for mortar and concrete. It covers fibres
to be used for sprayed concrete, concrete floors, precast concrete elements and for concrete
and mortar for repair work.
EN 14889-2: Fibres for concrete Part 2: Polymer fibres Definitions, specifications and
conformity
This Standard defines requirements for polymer fibres for mortar and concrete. It covers
fibres for load-bearing and non-load-bearing purposes including the use in sprayed concrete,
concrete floors, precast concrete elements, tunnel facing and repair work. This standard is
being revised.
3.2
i.
ii.
EN 14650 Precast concrete products General rules for factory production control of
metallic fibred concrete.
iii.
iv.
Austria:
VBB
Richtlinie
Erhht
brandbestndiger
Beton
fr
unterirdische
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vi.
vii.
Italy: UNI 11039 Steel fibre reinforced concrete Part I: Definitions, classification,
specification and conformity Part II: Test method for measuring first crack strength
and ductility, 02/2003.
viii.
ix.
Norway: Publication Nr.7, Sprayed concrete for rock support, Norwegian concrete
association
x.
xi.
xii.
UK: Concrete Society Technical Report no 63 - Guidance for the Design of Steel-FibreReinforced Concrete. Blackwater, Camberley, Surrey, 2007.
xiii.
xiv. Rilem TC 162 TDF Design of Steel fibre reinforced concrete Method,
recommendations, Material and Structures, 2002.
xv.
fib Model Code 2010 First complete draft, Volume 1, and 2, Bulletin 55, 3/2010.
xvi. EFNARC European Specification for sprayed concrete, Guidelines for specifiers and
contractors, 1996.
3.3
ASTM C1609/C1609M
ERMCO
EN 14651
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A draft
amendment is in preparation.
EN 14721
EN 14845-1: 2007
EN 14845-2: 2006
EN 14488-7: 2006
is
also
rather
low
(1-2
kg/sample).
JSCE-SF4
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(xii)
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5 Constituents
5.1
General
The requirements for the constituents of fibre concrete are the same as those for concrete
conforming to prEN 206.
5.2
Fibres
5.2.1 CE marking:
Steel and polymer fibres may be used in concrete in Europe only if they conform to the
requirements of EN 14889 and are CE- marked (European Conformity). Conformity to this
standard indicates established suitability of the fibres for some use in concrete.
NOTE: CE-marking is currently not mandatory in all EU countries, but will be so when the
Construction Products Regulation comes into force in 2013.
The basic information given in the CE marking is the following:
CE Certification;
tensile strength;
Youngs modulus;
length;
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tolerances on the length, the diameter (and the aspect ratio for steel fibres);
safety aspects.
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Figure 1a/1b: Example of CE labelling of steel (1b) or polymer (1a) Class II fibre
For CE-marking of fibres, two levels of attestation of conformity are defined: System 1 and
System 3
System 1 is applicable when the fibres have a structural function, i.e. when the fibres are
designed to contribute to the load-bearing capacity.
surveillance of the production process of the fibres by an independent Certifying Body, which
delivers a certificate of conformity (CE- mark).
System 3 is applicable when fibres are used for other reasons, i.e. for some non-structural
function - for instance to reduce the risk of plastic shrinkage, or to improve the behaviour of
concrete in fire. This system allows the manufacturer alone to declare that the quality is in
accordance with the requirements of the standard: no confirmation by a third party is
necessary.
In practice, therefore, when the post-crack strength of fibre concrete is taken into account in
the structural design, the fibres must be certified under System 1, and the CE label on the
packaging must indicate that the fibres are certified for structural use (System 1).
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System 1
System 3
Field of use
Structural use A)
Quality control
A)
Structural use of fibres is where the addition of fibres is designed to contribute to the load bearing
capacity of a concrete element
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The residual flexural tensile strength of fibre concrete is a key performance parameter. It is
dependent on the type and amount of fibres added, as well as the properties of the concrete
matrix itself.
Figure 3 is a typical load-deflection diagram for the 4-point beam test shown in figure 4. The
non-fibre concrete shows no residual flexural tensile strength, whilst the fibre concrete
retains around 30% of the maximum flexural tensile strength. The amount of residual
strength retained depends on the type of fibre used and the quantity per cubic metre.
Generally for the same performance the ratio between steel and macro polymer fibres is 5:1
(i.e. 25 kg/m3 steel fibre is equivalent to 5 kg/m3 of macro-polymer fibres).
20
15
10
4,5
3,5
2,5
1,5
0,5
load [kN]
25
deflection [mm]
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Figure 4: Four-point beam test for the identification of the load deflection diagram
(photograph courtesy of Krampe Harex)
Youngs modulus:
tensile strength:
design:
length:
20 60 mm;
cross section:
diameter:
surface:
Figure
6:
Shaved
cold
drawn
wire
(Drahtsegmentfaser)
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Steel fibres with a high aspect ratio are usually in glued strips to avoid balling when mixed
into concrete, see figure 9. The glue is dissolved in the mixing water and the fibres separate
during mixing.
tensile strength
design
length
20 60 mm;
cross section
300-1300 m;
50-2000 m;
surface
smooth or embossed.
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Class II: macro-fibres, 0,30mm in diameter. These have the same dimensions as
steel fibres.
the cross section, together with the surface characteristics, Youngs modulus and the
tensile strength, determine the bond between the fibres and the concrete;
tensile strength:
design:
length:
3 36 mm;
cross section:
circular or rectangular;
diameter
10-50 m;
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smooth.
Micro-polymer fibres are not subject to splitting so are free from the health risk referred to in
section 11.5.
6.1
Consistence
The addition of fibres to concrete may reduce the slump and/or increase the cohesiveness of
the mix. This has to be compensated for by either the use of plasticisers or by adjusting the
mix proportions.
misleading and it may not be necessary to compensate for this apparent low consistence. If
fibres are added at the plant under the responsibility of the concrete producer, the end18/39
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consistence (at site) requested by the contractor must be provided by the producer. If fibres
are added at the job-site by the concrete producer a loss of consistence is likely, and the
producer must allow for this in mix design and in batching. In both situations the producer is
responsible for the concrete properties and is required to show conformity of the concrete on
delivery.
If fibres are added under the responsibility of the contractor, the producer is responsible only
for the concrete prior to the addition of the fibres, and the fibre addition and any other
changes to the concrete made by the contractor are the responsibility of the contractor, e.g.
the addition of plasticisers, or superplasticisers to compensate for any loss of consistence.
As with normal concrete, the addition of water alone to correct the consistence will adversely
affect the quality of the fibre concrete. As the producers conformity is limited to the concrete
prior to the addition of fibres, the client is advised to require testing of the concrete after the
fibres have been added if they have been added under the responsibility of the contractor .
6.2
Pumpability
Pumping fibre concrete does not require special equipment. However, it is useful to have a
vibrator on the grid of the pump.
Concrete containing short fibres of any type will not cause problems. However, longer steel
or macro-polymer fibres with an aspect ratio of more than about 60 may require careful
attention to mix design, particularly at high dosages (typically, more than 25 kg/m of steel
fibres, or more than 10 kg/m of macro-polymer fibres). This is very much dependent on the
type of fibre being used and the fibre supplier should be able to advise on these aspects. It
is recommended that the diameter of the pump pipeline should not be less than one and a
half times the length of the fibres used for steel fibres but can be smaller for macro-polymer
fibres as they exhibit some flexibility in the pipeline.
In practice, and with care, good results can be achieved even with 60 mm steel or macropolymer fibres (at low dosages of 20 to 25 kg/m of steel fibres or 4-6 kg/m macro-polymer
fibres) in 63 mm and 76 mm hoses. As with all concrete types, pumpability is much more a
matter of mix design, proper consistency, good lubrication of the pump and all lines
beforehand, and attention to controlling the pressure of the pump
For concrete containing more than about 35 kg/m steel fibres or 10 kg/m3 of macro-polymer
fibres, or in the case of long or complicated pump lines, pumping difficulties may be
experienced despite proper adjustments of the mix design. In this case, concrete producers
are advised to take contractual steps to clarify responsibility, and in agreement with the
contractor, conduct pumping trials before work starts.
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Air content
Adding fibres can influence the air content of any concrete. The European standards 148991 and - 2 make no mention of this. The use of coatings on some fibres was mentioned in
section 5.2.4.
These, together with the use of some plasticisers, may increase the air
content of the concrete. A compatibility test should be undertaken before the production of
the concrete to ensure no adverse interactions of admixtures (see section A.3) and that the
required strength is achieved.
6.4
Bleeding
The addition of steel fibres or macro-polymer fibres has little effect on rate of bleeding, but
polymer micro-fibres can significantly reduce both the rate and volume of bleeding.
6.5
It is recognised that plastic shrinkage and cracking are related to bleeding and/or
autogenous/chemical shrinkage. Polymer micro-fibres may therefore have beneficial effects,
while steel and macro-polymer fibres have little influence. This is one of the principal reasons
for the use of polymer micro-fibres, particularly in horizontal elements. If fibres of this type
are used for this purpose, typical addition rates range between 600 g/m and 900 g/m.
General
Fibres are mainly added to influence the hardened concrete properties. Many of the
hardened properties which are affected are rarely specified, and are unlikely to be familiar to
ready-mixed concrete producers.
Steel and macro-Polymer fibres significantly affect hardened properties in the following
ways:
Figures 12 to 14 illustrate the principal influences of different types of steel and macropolymer fibres on the properties of the concrete.
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load
deflection
Figure 12: Post-crack flexural tensile strength of concrete with fibres of different aspect
ratios, the same length and the same fibre content (kg/m).
load
long fibres
short fibres
deflection
Figure 13: Post-crack flexural tensile strength of concrete with fibres of different length, the
same aspect ratio and the same fibre content.
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load
deflection
Figure 14: Post-crack flexural tensile strength of concrete with fibres of different designs and
same fibre content.
Polymer micro-fibres significantly affect hardened properties in the following way:
7.2
Compressive strength
The addition of fibres usually does not affect compressive strength except where the air
content is increased, for example by the fibre coating (see 5.2.4).
7.3
The ability of fibres to transfer stresses across cracks is one of the most important properties
of fibre concrete. It enables a fibre-reinforced structure to maintain substantial load even after
a crack has developed. In 95% of cases, steel and macro-polymer concrete will show
behaviour in pure tension like that in Figure A.1 in Annex A. However, since a uniaxial
tensile test is difficult to perform, flexural tensile strength is usually tested see sections 9.2,
9.3 and Annex A. However, axial tensile strength can be calculated from the post-crack
flexural tensile strength by means of conversion factors.
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Post-crack flexural tensile strength is assessed in a 3-point beam test (EN 14651) or in a 4point beam test. Both methods are used and the results in numerical terms will not
necessarily be the same.
For statically determined structures subjected to a flexural moment it is common to refer to
the residual load bearing capacity as post-crack flexural tensile strength.
At normal addition rates (typically between 20-40 kg/m of steel fibres or 4-8 kg/m of macropolymer fibres), the post-crack flexural tensile strength is less than the flexural tensile
strength at the first crack.
Bending hardening, which refers to the situation where the post-crack flexural tensile
strength is higher than the first-crack flexural tensile strength, can occur at dosages above 50
kg/m of steel fibres with high aspect ratios.
7.4
Fire resistance
The fire resistance of concrete structures is generally considered not to be influenced by the
addition of steel fibres, though the fibres may reduce the degree of spalling somewhat by
bridging areas of spalled concrete.
Macro-polymer fibres will contribute to a concretes fire resistance, but will not be as effective
as micro-polymer fibres. As they melt at 160C, they cannot be considered as structural
reinforcement at higher temperatures.
As shown in figure 15, spalling of concrete in a fire is reduced by the addition of an adequate
dosage of polymer micro-fibres (diameter 3 to 32 m), typically 1-2 kg/m3. In Austria a
guideline for the fire resistance of fibre concrete, including test methods and requirements for
the fibres was published in 2005 [iv].
[iv]
: on the left a
7.5
Impact resistance
Impact resistance, ductility and toughness are generally increased by the addition of any
fibres. When impact resistance is required, design is usually determined by testing and then
the concrete is specified by type and fibre content.
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Shear resistance
The addition of steel fibres to concrete will enhance the shear resistance of structural
elements. A ductile failure mode is induced, in the same way as by the use of reinforcement
stirrups. A number of standards and guidelines contain an equation describing the effect of
steel fibres as equivalent shear reinforcement (xii).
The shear resistance of steel fibre concrete is based upon the post-crack flexural tensile
strength, determined from standardized beam tests (Annex A.)
7.7
Durability
While steel fibres may reduce the risk of spalling due to corrosion of reinforcement, they do
not reduce the rate of corrosion or the rate of loss of cross section.
Corrosion of steel fibres themselves at the surface does not cause any spalling. Designers
should consider the use of steel fibres in potentially corrosive conditions if the fibres near to
the surface contribute to structural performance.
Both steel and macro synthetic fibres improve abrasion resistance.
Polymer fibres have a positive effect on durability by reducing the incidence of early age
shrinkage cracking. Polymer micro-fibres increase the fire resistance of concrete structures
by reducing spalling.
7.8
Creep
The importance of steel and macro-polymer fibres in increasing the post-crack flexural tensile
strength of concrete has been explained in section 7.3. However, the influence of creep
must be taken into account. The post-crack flexural tensile strength of polymer macro-fibrereinforced concrete may be initially equal to that of steel fibre-reinforced concrete, but the
long term behaviour may be different. Under permanent load the polymer fibres themselves
have a tendency to creep, and fibre failure or large creep deformations may eventually occur
in both the fibres and the concrete. This is something that has to be taken into account in the
structural design.
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The properties described above, together with the choice of the type and quantity of fibres
added (particularly those with high aspect ratio, or those used at high dosage rates) may
require modifications to mix design, e.g. to compensate for any loss of consistence. The use
of fibres in concrete requires initial type testing as concrete properties are affected. Changes
necessary to mixes may include the following:
when fibres are used with concrete of low compressive strength class and/or pumped
concrete, the demand for cement paste is typically increased;
the additional surface area of fibres may necessitate a larger mortar content to
minimise the risk of harsh concrete, which is difficult to finish;
the surface coating on fibres may influence fresh concrete properties, primarily the air
content, and assessment is required at this stage. It may be necessary to use a
different admixture, or even a different fibre.
possibility of air entrainment when fibres are added to concrete. A possible way to
minimise this risk is described in 9.3 Practice in Europe / Austria (Testing of the
influence of fibres on the air content of concrete).
the maximum aggregate size should not exceed the length of the fibre.
PrEN 206 Concrete requires initial testing to verify that the producers documented mixing
procedure ensures a homogeneous distribution of fibres and a procedure for verifying this
requirement is given. This includes the situation where the mixing is undertaken in a
truckmixer under the responsibility of the concrete producer.
9 Specification
Broadly speaking, there are two methods of specification available: specification by fibre type
and content, and specification by performance of the fibre concrete. Where fibre type and
content are specified, this may be within a designed concrete or a prescribed concrete.
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The simplest and most common method is for the specifier to define the fibre type and the
fibre content per m (specified as a minimum quantity) that should be included in the
concrete. The concrete suppliers responsibility is limited to adding and mixing the right type
and quantity of fibres and ensuring that the fibres are homogeneously mixed, together with
the other specified requirements e.g. consistence, compressive strength class. The specifier
takes responsibility for the additional performance resulting from the addition of fibres e.g.
post-crack flexural tensile strength.
Where fibres are to be added under the responsibility of the contractor, the contractor must
specify to the producer a concrete that takes account of the changes the fibres will make to
the concrete properties.
9.2
PrEN 206 does not describe in detail this method of specification, and is limited to a
statement that details have to be agreed between the specifier and the concrete producer. In
some countries (e.g. Austria and Germany) fibre concrete is specified by performance
classes established in national provisions ((iii) (vi)) These classes may be based on properties
such as post-crack behaviour in ultimate and serviceability limit states, flexural tensile
strength, fire resistance, and early-age shrinkage. The producer is responsible for the design
and performance of the concrete, including decisions on fibre type and content. However, in
most countries, ready-mixed concrete producers have still to develop the expertise to design
concrete in this way. PrEN 206 states that if fibre concrete is specified in this way, the test
method and conformity procedures must be agreed with the concrete producer.
Some producers have a number of proprietary designs, with stated performance, from
which a specifier may choose.
9.3
Practice in Europe
In most European countries specification of fibre concrete is simply done by fibre type and
content. The fibre content is often determined by the supplier of fibres, in discussion with the
design engineer. The agreed fibre type and content are then specified to the concrete
supplier. This is the usual practice in, for example, the Czech Republic, Denmark, Finland,
France, Netherlands, Norway, Poland, Portugal, Slovakia and the United Kingdom.
Some examples of national practice in methods of specification are given in the following
sub-sections.
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Austria
Austria has a guideline for steel fibre concrete
(iii)
Achieving the required performance of the steel fibre concrete depends on the steel fibre
type (e.g. length, diameter) and content (e.g. 15 or 25 kg/m) and the properties of the
concrete itself. It is the producers responsibility to design the concrete to conform to the T
and G classes specified.
The guideline also includes performance classes for flexural tensile strength (classes BZ 3.0,
BZ 4.5 and BZ 6.0) with minimum characteristic flexural tensile strengths of 2.2, 3.2 or 4.2
N/mm respectively.
A performance specification for the reduction of early age shrinkage for polymer fibre
concrete is also included the single FS performance class requires reduction of the total
crack length to 20% of that of the same concrete without fibres.
A separate Guideline
(iv)
concrete. Special test methods and specimens have been developed see figure 15. This
fibre concrete is often used for tunnelling and subway construction. In addition the new
revision of this guideline will set requirements on the increase in air content. Practice in
Austria shows that testing on mortar is sufficient to determine the change in air content. The
difference between the air content of the mortar with polymer micro-fibres and the mortar
without fibres has to be less than about 2%. Similar testing is possible and useful for steel
fibres. The test has to be made with every new delivery of fibres (or every 6 months) by an
independent laboratory under the responsibility of the fibre producer or the fibre supplier.
For conformity there is no requirement for routine performance testing.
requirements firstly the delivery tickets must state that the fibres used are the same as
those used in initial type testing. Secondly, the fibre content of fresh concrete is verified with
a wash out test described in the Guideline (iii).
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Any need for identity testing has to be determined by the client and undertaken by the clients
representative. The procedures for identity testing are the same as for conformity
assessment and the criteria are also the same.
Czech Republic
In the Czech Republic specification is usually by fibre content, but one supplier offers a fibre
concrete with a description including tensile strength class.
Germany
Germany has a system of performance classes (post-crack flexural tensile strength), which
are used for specification. The determination of the performance class is part of the initial
testing of the producer. Six beams (150 mm x 150 mm x 700 mm) are tested in a four point
flexural test to determine the characteristic value of post-crack flexural tensile strength.
Two performance parameters (L1 and L2) are defined. L1 is determined at the point of 0,5
mm deflexion of the beam test. L2 at the point of 3,5 mm deflexion. Nine classes are defined
with values of L1 and L2 between 0 and 2,4 N/mm. The initial testing of the fibre concrete is
undertaken with the minimum fibre content planned by the producer for each mix design for
later continuous production. Conformity to the performance class of each fibre concrete is
verified yearly by retesting. Routine conformity is assessed by testing of the fibre content and
documentation of the type of fibre. Fibre concrete is then specified by compressive strength
class, exposure class and performance class. Identity testing of fibre content may be done
by the customer. The national regulations are published in Richtlinie Stahlfaserbeton (2010)
(vi)
Example: A fibre performance class C30/37 L 1,8/1,5 corresponds in practice with a C30/37
mix, reinforced with around 30 kg/m of a high-end steel fibre with aspect ratio 80, length 60
mm, hooked end, and a nominal tensile strength of 1200 MPa.
A performance class C30/37 L 0,9/0,6 corresponds in practice with a C30/37 mix, reinforced
with around 30 kg/m of a low-end steel fibre with aspect ratio 45, length 50 mm, hooked
end, and a nominal tensile strength of 1100 MPa.
Sweden
In Sweden while specification is, as elsewhere, usually by fibre content, performance
requirements are sometimes stated. In accordance with Concrete Report No 4(X) (a Swedish
design guideline for fibre-reinforced concrete) the performance is often expressed by means
of residual strength factors or R-values, which is the ratio of the post-cracking flexural tensile
strength and the flexural tensile strength. This is determined by initial testing and it is unusual
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for routine performance tests to be carried out to verify the performance established during
initial testing.
UK
In UK, specification is normally by type and content of fibres, but some ready-mixed
companies offer a statement of performance for their proprietary concrete. Conformity by
performance testing is not usually assessed.
10 Conformity
Conformity is a matter for the producer and part of factory production control.
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In the case of Germany, where post-crack flexural tensile strength is specified, the producer
is required to demonstrate performance in initial-type testing, then subsequently once a year;
but for conformity purposes, only fibre content is assessed.
that the fibres are evenly distributed throughout the concrete: in particular, balling of
the fibres must be prevented;
that the addition of fibres does not compromise other aspects of the specification of
the concrete.
The instructions on packaging are important. If fibres are packed in a double bag - the outer
bag has to be removed prior to adding to the concrete the water soluble inner bag containing
the fibres.
Most manufacturers of fibres prescribe preferred methods of batching to make sure that the
fibres will be evenly distributed in the mix and that the intended performance of the fibre
concrete will be achieved.
The fibres can be added directly to the central plant mixer or to the truck mixer. Generally,
fibres should not be added before the coarse aggregates. Slow addition reduces the
tendency to balling, particularly those fibres with problematic shape e.g. high aspect ratios
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(above 50) and high addition rates (more than about 35 kg/m steel fibres or 10 kg/m3 macropolymer fibres). Mixing recommendations from the manufacturer are useful.
11.2.1
Addition of fibres at the plant under the responsibility of the concrete producer is the best
way to ensure concrete quality. Fibres can be added directly into the truck mixer, or, to
optimise dispersion, into the plant mixer. Many producers will have established their own
batching procedures, but generally, the following advice is offered:
Where concrete is batched through a dry batch plant (i.e. truck mixing), for each bag of
fibres, approximately 35 litres of water per m3 should be added to the truck mixer prior to the
addition of the coarse aggregates and fibres. Mixing fibres with water only leads to balling.
Ideally, one hundred revolutions of the mixer is required to ensure good fibre distribution, but
in practice it is difficult to monitor this. More practically, therefore, a minimum mixing time of
five minutes (or one minute per m) at the maximum speed of the drum is required.
For reasons of safety, many ready-mixed concrete suppliers do not permit operatives to
access the platform at the back of the truck. In such cases it is necessary that a proper
system for adding the fibres to the truck mixer be used. One possible solution is to add bags
of fibres by means of a lance. Different automated or semi-automated systems exist.
Polymer fibres
Polymer fibres should be added to the truck mixer or central plant mixer with the coarse
aggregates or after the dosing of all other constituents; this aids the dispersion of the fibres
and helps in breaking up any degradable packaging.
If polymer fibres are added directly into to the truck mixer, it is particularly important to
ensure that thorough mixing takes place. The minimum practical consistence for working
with fibre concrete may be considered to be 40-50 mm. Therefore if the fibres are added
after the other constituents, the consistence should preferably be brought to an adequate
level beforehand to assist the dispersion of fibres. However, there is no clear agreement on
what this level should be: advised levels vary from 50 to 125 mm slump.
Steel fibres
These fibres should not be added at the start of the batching process, but only after the other
constituents are thoroughly mixed.
concrete. Recommended methods are to disperse the fibres on the aggregate conveyor or
into the weigh hopper by automatic means.
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11.2.2
For a number of reasons e.g. health and safety or to ensure proper mixing and for general
quality control considerations, many ready-mixed suppliers are unwilling to allow fibres to be
added on the job site. (This is also prohibited by some national regulations e.g. in Germany).
However, it is recognised that fibres are sometimes added to the concrete truck mixer at the
construction site.
If fibres are added under the responsibility of the contractor (at the plant or on site) the
responsibility for the concrete after adding the fibres has to be clearly declared in a written
form.
systems that are in operation to ensure the correct type and dosage/mass of fibres
are batched;
methods used to ensure fibre are dispersed homogeneously within the mixed
concrete;
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frequency of testing;
system that is to be used to evaluate the conformity of the fibre concrete with the
specification;
11.4 Transport
Generally, there are no special requirements for the transportation of fibre concrete.
General
It is the responsibility of the fibre manufacturer to provide the concrete supplier with any
necessary information, normally to be declared in the safety data sheet.
Fibres with diameter less than 3 m and an aspect ratio less than 3 may have associated
risks for human health, specifically breathing. Fibre fragments of such critical dimensions
may result from disintegration of the fibre when the concrete and fibres are subject to
mechanical stresses. The producer of the fibres has to declare this in his safety data sheet.
Under some national regulations the use of such fibres is not permitted.
Micro-polymer fibres are not subject to splitting and this potential health risk.
Generally the addition of macro-polymer fibres presents less Health and safety issues than
steel fibres because they are lighter and therefore easier to handle. They also do not a
puncture injury possibility.
11.5.2
For safety reasons, manual handling should be restricted to a minimum, and the use of a
conveyor is recommended. At present fibres, polymer or steel, are either added directly to
the truck mixer using pre-weighed soluble or insoluble bags or boxes, or delivered directly to
a static, central mixer in a continuous fashion (ribbon feeding).
manual handling;
working at heights;
risk to eyes;
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The method for placing the fibres into the back of the ready-mixed concrete truck may be:
In both cases, the fibres need to be manually lifted to be either placed on the conveyor belt
or into the mixer drum. Sometimes, inadvisably, ladders are used. Specific potential risks
arise from each of these methods of working:
Specific potential risks arising from use of conveyor belts:
manual lifting of bags of fibres onto conveyor belt (risk of back injury);
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Conformity to a specified minimum fibre content is assessed in the same way as for example
the minimum cement or additions content. It is based on the documentation of the fibre
content - the fibre content is to be taken either as the recorded value on the print-out of the
batch recorder, or where recording equipment is not used, from the production record in
connection with the batching instruction. An assessment is required at least once a day.
The fibre content is specified by a minimum value. PrEN 206 gives the lower limit for
conformity for steel fibre content (single test) as the specified value multiplied by 0.95 and for
polymer fibre content 0.9 assessed in both cases on the production record. As for other
properties, conformity testing of fibre content is based on testing by variables in accordance
with ISO 3951:1994 table II-A (AQL = 4 %).
Where the fibres are added at the truck mixer on site there is a further conformity
requirement for homogeneity of mixing through the load, tested at the same frequency as for
compressive strength. This test is based on testing individual values. It follows the same
principle as for testing fresh concrete consistence or air content. Conformity criteria and the
criteria for possible identity testing by the customer are the same.
Criterion
0,80 of the specified
minimum value
0,85 of the specified
minimum value
In practice it is not easy to meet these requirements, particularly with polymer micro-fibres,
and there is no certainty that the test method in standard EN14488-7 is valid for micro-fibre
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concrete. In some cases, to ensure conformity, producers have had to increase the fibre
content rate by 10 to 20%.
Provision of information
12.4.2
Batching tolerances
The batching tolerances for fibres are the same as for admixtures and additions. The
tolerance is 3 % of required quantity where the mass of fibres used is more than 5 % by
mass of cement and 5 % where the mass of fibres is 5 % or less, by mass of cement.
12.4.3
Batching procedure
Fibres are added during the main mixing process or in a second mixing operation in the
truck. When fibres are added in the truck mixer, the concrete has to be re-mixed until the
fibres have been completely dispersed throughout the batch.
13 Recommendations
The following recommendations are made:
1. More research or information is needed about the risk of introducing air into concrete by
the addition of fibres. The supplier of the fibres should be required to demonstrate that
they do not unduly increase air content of the concrete or give a consistent increase in
the air content. (see 9.3 Practice in Europe / Austria).
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Pcr is the load at which the matrix cracks. The fibres only play a role after first cracking and
they influence the displacement area starting from Pcr.
Figure A.1: Axial tensile test (source: fib Model Code 2010: draft version 2010 (xv))
between the two central loading points, i.e. a larger area. The larger the area, the higher is
the probability that this will contain a weaker link that precipitates cracking. Consequently a
four-point beam test is likely to give a lower flexural tensile strength than a three-point test.
As explained in section 7.3, the beam test is used to assess the performance of fibre
concrete. EN14651: Test method for metallic fibre concrete - Measuring the flexural tensile
strength, describes the European beam tests for steel fibre concrete.
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Figure A.2: Three-point flexural beam test for steel fibre concrete (source EN
14651)
fR,j
Fj
l
b
hsp
post-cracking flexural
tensile strength
load (jCMOD)
span (see figure A.2)
beam width
beam depth
(xv)
Austria, Italy, Spain, have introduced their own design standards for steel fibre concrete. All
these design standards make use of the post-crack flexural tensile strength of steel fibre
concrete, but the beam tests vary from country to country (three- or four-point beam tests),
and producers should familiarize themselves with the type of beam test applicable in place
of use of the concrete.
This property is used in performance specification. Germany and Austria, for example,
have established post-crack flexural tensile strength performance classes for use in
specification (see 9.3).
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