Carbon fiber reinforced concrete (Carbocrete)

Aly Attia Ihab Khalil Fathy Abdel Halim Mohamed Mubarak Presented to: Dr. Mohamed Nagib Abou-Zeid Carbocrete The American University In Cairo School Of Science And Engineering Department Of Construction and Architectural Engineering  What is Carbocrete?  History of carbon fibers  Manufacturing of carbon fibers  Carbon fibers in construction  Carbon fibers vs. steel (Properties)  Carbocrete Mixing  Testing  Key properties of Carbocrete  Advantages & disadvantages  Economic aspects  Applications  Conclusion  References Outline  It is a type of concrete that is reinforced with carbon fibers so it’s also known as “Carbon Reinforced Concrete”.  It is a new highly stressable lightweight composite construction that combines special fine grain ultra high-strength concrete and carbon fibers.  It has higher strength than steel with quarter of its weight. What is Carbocrete? Carbocrete http://www.haute-innovation.com  In late 1800s, Thomas Edison was the first to use carbon fibers as filaments for early light bulbs.  It lacked the high tensile strength of today’s carbon fibers; however he used it because of their high tolerance to heat which made these fibers ideal for conducting electricity. History of Carbon Fibers Thomas Edison www.biography.com Filament en.wikipedia.org  It wasn’t until the late 1950 that high-performance carbon fibers was manufactured by Mitsubishi Rayon  The USA’s Air Force and NASA didn’t wait develop the carbon fiber technology and began to use carbon fiber reinforced polymers to replace heavy metals to allow aircrafts to be lighter and faster. History of Carbon Fibers (Cont’d) Carbon fiber aircraft propeller pics1.this-pic.com Manufacturing of Carbon Fibers  Raw carbon fiber is made from either polyacrylonitrile (PAN) or petroleum coal.  These fossil-fuel- based materials come from either petroleum refining or natural gas processing Petroleum coal www.c-chem.co.jp PAN www.c-chem.co.jp  1st: in the thermoset treatment, the fibers are stretched and heated to no more than 400° C  2nd: in the carbonize treatment, the fibers are heated to about 800° C in an oxygen free environment to remove non-carbon impurities.  3rd: fibers are graphitized; this step stretches the fibers between 50 to 100% elongation, and heats them to temperatures ranging from 1100° C to 3000° C. The stretching ensures a preferred crystalline texture, which results in the desired tensile strength.  4th: the last two treatment steps, surface treatment and epoxy sizing, are preformed to enhance the carbon fiber bonding strength. Manufacturing of Carbon Fibers (Cont’d) Manufacturing of Carbon Fibers (Cont’d) PAN Manufacturing Process www.arrhenius.ucsd.edu Carbon Fiber in Construction  Carbon fibers are mostly used for repair purposes of old structural element against shear and flexure failure; the material know as CFRP.  However, in the early 1990s, researches showed that carbon fibers can be used inside the concrete instead of steel reinforcement showing a significant improvement in the flexural and tensile strength of concrete. http://www.carbonwrapsolutions.com www.sglgroup.com Carbon Fibers vs. Steel  Up to 75% lighter  More durable/corrosion-free  5 times higher tensile strength  2 times higher stiffness  Higher temperature tolerance Comparison of Fiber Strengths www.innovationskraftwerk.de [...].. .Carbon Fibers vs Steel (Cont’d) Comparison Between Carbon Fibers and Steel Fibers www.innovationskraftwerk.de Carbocrete Mixing Method  Methods:  Dry mix  Wet mix Mixing Methods http://wings.buffalo.edu Carbocrete Mix Design Mix Design... http://www.carbonwrapsolutions.com  http://www.toray.com  http://www.biography.com  http://www.sglgroup.com  http://www.haute-innovation.com/de/vortraege-diskussionen/werkstoffe-fuer- nachhaltiges-bauen.html  http://www.youtube.com/watch?v=Ux1yIpGO7p8  http://www.innovationskraftwerk.de/Wettbewerb/sgl /Carbon- Beton/Details/38  http://wings.buffalo.edu/academic/department/eng/mae/cmrl /Concrete% 2 0reinforced. .. http://www.innovationskraftwerk.de/Wettbewerb/sgl /Carbon- Beton/Details/38  http://wings.buffalo.edu/academic/department/eng/mae/cmrl /Concrete% 2 0reinforced %20with%20up%20to%20vol%20of%20short%2 0carbon% 20fibers.pdf  http://www.utsi.edu/research/carbonfiber/cf.htm Thank you ... www.toray.com Economic Aspects (Cont’d) www.utsi.edu Applications  Limited applications  In 2012, SGL Group launched a competition among innovative engineers to answer the question "What can I make from carbon concrete? „  A total of 319 ideas were submited Applications (Cont’d)  Carbocrete Balcony www.sglgroup.com Applications (Cont’d)  Shore protection seashells www.sglgroup.com Applications (Cont’d) . the carbon fiber technology and began to use carbon fiber reinforced polymers to replace heavy metals to allow aircrafts to be lighter and faster. History of Carbon Fibers (Cont’d) Carbon fiber. Architectural Engineering  What is Carbocrete?  History of carbon fibers  Manufacturing of carbon fibers  Carbon fibers in construction  Carbon fibers vs. steel (Properties)  Carbocrete Mixing  Testing  Key. enhance the carbon fiber bonding strength. Manufacturing of Carbon Fibers (Cont’d) Manufacturing of Carbon Fibers (Cont’d) PAN Manufacturing Process www.arrhenius.ucsd.edu Carbon Fiber in Construction  Carbon