Formation of Protective Aluminum-Oxide Layer on the Surface of Fe-Cr-Al Sintered-Metal-Fibers via Multi-Stage Thermal Oxidation

The objective of this paper is to investigate the formation and adhesion of a protective aluminum-oxide (Al2O3, alumina) layer on the surface of Iron-Chromium-Aluminum Alloy (Fe-Cr-Al) sintered-metal-fibers. The oxide-scale layer was developed via multi-stage thermal oxidation at 930 oC for 1 hour, followed by 1 hour at 960 oC, and finally at 990 oC for 2 hours. Scanning Electron Microscope (SEM) images show that the multi-stage thermal oxidation resulted in the formation of predominantly Al2O3 platelets-like and whiskers. SEM images also reveal non-uniform oxide-scale growth on the surface of the fibers. Furthermore, peeling/spalling of the alumina protective layer occurred after minimum handling, which indicates weak adhesion forces between the protective layer and the base metal alloy.  Energy Dispersive Spectroscopy (EDS) analysis of the heat-treated Fe-Cr-Al sintered-metal-fibers confirmed the high aluminum content on the surface of the protective layer, and the low aluminum content on the exposed base metal alloy surface. In conclusion, the failure of the oxide-scale protective layer exposes the base metal alloy to further oxidation, and the fragile non-uniform oxide-scale is not suitable as a support for catalysts.

Stress-Strain Relation for Hybrid Fiber Reinforced Concrete at Elevated Temperature

The performance of concrete structures in fire depends on several factors which include, among others, the change in material properties due to the fire. Today, fiber reinforced concrete (FRC) belongs to materials which have been widely used for various structures and elements. While the knowledge and experience with FRC behavior under ambient temperature is well-known, the effect of elevated temperature on its behavior has to be deeply investigated. This paper deals with an experimental investigation and stress‑strain relations for hybrid fiber reinforced concrete (HFRC) which contains siliceous aggregates, polypropylene and steel fibers. The main objective of the experimental investigation is to enhance a database of mechanical properties of concrete composites with addition of fibers subject to elevated temperature as well as to validate existing stress-strain relations for HFRC. Within the investigation, a unique heat transport test, compressive test and splitting tensile test were performed on 150 mm cubes heated up to 200, 400, and 600 °C with the aim to determine a time period for uniform heat distribution in test specimens and the mechanical properties of the investigated concrete composite, respectively. Both findings obtained from the presented experimental test as well as experimental data collected from scientific papers so far served for validating the computational accuracy of investigated stress-strain relations for HFRC which have been developed during last few years. Owing to the presence of steel and polypropylene fibers, HFRC becomes a unique material whose structural performance differs from conventional plain concrete when exposed to elevated temperature. Polypropylene fibers in HFRC lower the risk of concrete spalling as the fibers burn out shortly with increasing temperature due to low ignition point and as a consequence pore pressure decreases. On the contrary, the increase in the concrete porosity might affect the mechanical properties of the material. To validate this thought requires enhancing the existing result database which is very limited and does not contain enough data. As a result of the poor database, only few stress-strain relations have been developed so far to describe the structural performance of HFRC at elevated temperature. Moreover, many of them are inconsistent and need to be refined. Most of them also do not take into account the effect of both a fiber type and fiber content. Such approach might be vague especially when high amount of polypropylene fibers are used. Therefore, the existing relations should be validated in detail based on other experimental results.

A Review on Concrete Structures in Fire

Concrete as a construction material is versatile because it displays high degree of fire-resistance. Concrete’s inherent ability to combat one of the most devastating disaster that a structure can endure in its lifetime, can be attributed to its constituent materials which make it inert and have relatively poor thermal conductivity. However, concrete structures must be designed for fire effects. Structural components should be able to withstand dead and live loads without undergoing collapse. The properties of high-strength concrete must be weighed against concerns about its fire resistance and susceptibility to spalling at elevated temperatures. In this paper, the causes, effects and some remedy of deterioration in concrete due to fire hazard will be discussed. Some cost effective solutions to produce a fire resistant concrete will be conversed through this paper.

Investigation of Rehabilitation Effects on Fire Damaged High Strength Concrete Beams

When high strength reinforced concrete is exposed to high temperature due to a fire, deteriorations occur such as loss in strength and elastic modulus, cracking and spalling of the concrete. Therefore, it is important to understand risk of structural safety in building structures by studying structural behaviors and rehabilitation of fire damaged high strength concrete structures. This paper aims at investigating rehabilitation effect on fire damaged high strength concrete beams using experimental and analytical methods. In the experiments, flexural specimens with high strength concrete are exposed to high temperatures according to ISO 834 standard time temperature curve. From four-point loading test, results show that maximum loads of the rehabilitated beams are similar to or higher than those of the non-fire damaged RC beam. In addition, structural analyses are performed using ABAQUS 6.10-3 with same conditions as experiments to provide accurate predictions on structural and mechanical behaviors of rehabilitated RC beams. The parameters are the fire cover thickness and strengths of repairing mortar. Analytical results show good rehabilitation effects, when the results predicted from the rehabilitated models are compared to structural behaviors of the non-damaged RC beams. In this study, fire damaged high strength concrete beams are rehabilitated using polymeric cement mortar. The predictions from the finite element (FE) models show good agreements with the experimental results and the modeling approaches can be used to investigate applicability of various rehabilitation methods for further study.

Bridging Stress Modeling of Composite Materials Reinforced by Fibers Using Discrete Element Method

The problem of toughening in brittle materials reinforced by fibers is complex, involving all of the mechanical properties of fibers, matrix and the fiber/matrix interface, as well as the geometry of the fiber. Development of new numerical methods appropriate to toughening simulation and analysis is necessary. In this work, we have performed simulations and analysis of toughening in brittle matrix reinforced by randomly distributed fibers by means of the discrete elements method. At first, we put forward a mechanical model of toughening contributed by random fibers. Then with a numerical program, we investigated the stress, damage and bridging force in the composite material when a crack appeared in the brittle matrix. From the results obtained, we conclude that: (i) fibers of high strength and low elasticity modulus are beneficial to toughening; (ii) fibers of relatively high elastic modulus compared to the matrix may result in substantial matrix damage due to spalling effect; (iii) employment of high-strength synthetic fibers is a good option for toughening. We expect that the combination of the discrete element method (DEM) with the finite element method (FEM) can increase the versatility and efficiency of the software developed. The present work can guide the design of ceramic composites of high performance through the optimization of the parameters.

Behaviour of Lightweight Expanded Clay Aggregate Concrete Exposed to High Temperatures

This paper is concerning the issues of behaviour of lightweight expanded clay aggregates concrete exposed to high temperature. Lightweight aggregates from expanded clay are produced by firing of row material up to temperature 1050°C. Lightweight aggregates have suitable properties in terms of volume stability, when exposed to temperatures up to 1050°C, which could indicate their suitability for construction applications with higher risk of fire. The test samples were exposed to heat by using the standard temperature-time curve ISO 834. Negative changes in resulting mechanical properties, such as compressive strength, tensile strength, and flexural strength were evaluated. Also visual evaluation of the specimen was performed. On specimen exposed to excessive heat, an explosive spalling could be observed, due to evaporation of considerable amount of unbounded water from the inner structure of the concrete.

Physical and Thermo-Physical Properties of High Strength Concrete Containing Raw Rice Husk after High Temperature Effect

High temperature is one of the most detrimental effects that cause important changes in concrete’s mechanical, physical, and thermo-physical properties. As a result of these changes, especially high strength concrete (HSC), may exhibit damages such as cracks and spallings. To overcome this problem, incorporating polymer fibers such as polypropylene (PP) in concrete is a very well-known method. In this study, using RRH, as a sustainable material, instead of PP fiber in HSC to prevent spallings and improve physical and thermo-physical properties were investigated. Therefore, seven HSC mixtures with 0.25 water to binder ratio were prepared incorporating silica fume and blast furnace slag. PP and RRH were used at 0.2-0.5% and 0.5-3% by weight of cement, respectively. All specimens were subjected to high temperatures (20 (control), 300, 600 and 900˚C) with a heating rate of 2.5˚C/min and after cooling, residual physical and thermo-physical properties were determined.

Mechanical Properties and Released Gas Analysis of High Strength Concrete with Polypropylene and Raw Rice Husk under High Temperature Effect

When concrete is exposed to high temperatures, some changes may occur in its physical and mechanical properties. Especially, high strength concrete (HSC), may exhibit damages such as cracks and spallings. To overcome this problem, incorporating polymer fibers such as polypropylene (PP) in concrete is a well-known method. In high temperatures, PP decomposes and releases harmful gases such as CO and CO2. This study researches the use of raw rice husk (RRH) as a sustainable material, instead of PP fibers considering its several favorable properties, and its usability in HSC. RRH and PP fibers were incorporated in concrete at 0.5-3% and 0.2-0.5% by weight of cement, respectively. Concrete specimens were exposed to 20 (control), 300, 600 and 900°C. Under these temperatures, residual compressive and splitting tensile strength was determined. During the high temperature effect, the amount of released harmful gases was measured by a gas detector.

Development of a Bacterial Resistant Concrete for Use in Low Cost Kitchen Floors

The degrading effect due to bacterial growth on the structural integrity of concrete floor surfaces is predictable; this consequently cause development of surface micro cracks in which organisms penetrate through resulting in surface spalling. Hence, the need to develop mix design meeting the requirement of floor surfaces exposed to aggressive agent to improve certain material properties with good workability, extended lifespan and low cost is essential. In this work, tests were performed to examine the microbial activity on kitchen floor surfaces and the effect of adding admixtures. The biochemical test shows the existence of microorganisms (E.coli, Streptococcus) on newly casted structure. Of up to 6% porosity was reduced and improvement on structural integrity was observed upon adding mineral admixtures from the concrete mortar. The SEM result after 84 days of curing specimens, shows that chemical admixtures have significant role to enable retard bacterial penetration and good quality structure is achieved.

Performance of Concrete Grout under Aggressive Chloride Environment in Sabah

Service life of existing reinforced concrete (RC) structures in coastal towns of Sabah has been affected very much. Concrete crack, spalling of concrete cover and reinforcement rusting of RC buildings are seen even within 5 years of construction in Sabah. Hence, in this study a new mix design of concrete grout was developed using locally available materials and investigated under two curing conditions and workability, compressive strength, Accelerated Mortar Bar Test (AMBT), water absorption, volume of permeable voids (VPV), Sorptivity and 90-days salt ponding test were conducted. The compressive strength of concrete grout at the age 90 days was found to be 44.49 N/mm2 under water curing. It was observed that the percentage of mortar bar length change was below 1% for developed concrete grout. The water absorption of the concrete grout was in between the range of 0.88 % to 3.60 % under two different curing up to the age 90 days. It was also observed that the VPV of concrete was in the range of 0 % to 9.75 and 2.44% to 13.05% under water curing and site curing respectively. It was found that the Sorptivity of the concrete grout under water curing at the age of 28 days is 0.211mm/√min and at the age 90 day are 0.067 mm/√min. The chloride content decreased greatly, 90% after a depth of 15 mm. It was noticed that the site cured samples showed higher chloride contents near surface compared to water cured samples. This investigation suggested that the developed mix design of concrete grout using locally available construction materials can be used for crack repairing of existing RC structures in Sabah.

Analysis of Surface Spalling on a First Intermediate Roll in Sendzirmir Mills

A first intermediate roll of Sendzirmir mills was failure by surface spalling during operation. After analyzing by visual, stereo microscope, optical microscope, scanning electron microscope, glow-discharged spectrometer and hardness test, respectively, the results show that some voids and cracks existed on the contact surface as well as subsurface. Further examination verified inadequate hardness and inclusions were responsible for the failure of surface spalling.

Effects of Corrosion on Reinforced Concrete Beams with Silica Fume and Polypropylene Fibre

Reinforced concrete has good durability and excellent structural performance. But there are cases of early deterioration due to a number of factors, one prominent factor being corrosion of steel reinforcement. The process of corrosion sets in due to ingress of moisture, oxygen and other ingredients into the body of concrete, which is unsound, permeable and absorbent. Cracks due to structural and other causes such as creep, shrinkage, etc also allow ingress of moisture and other harmful ingredients and thus accelerate the rate of corrosion. There are several interactive factors both external and internal, which lead to corrosion of reinforcement and ultimately failure of structures. Suitable addition of mineral admixture like silica fume (SF) in concrete improves the strength and durability of concrete due to considerable improvement in the microstructure of concrete composites, especially at the transition zone. Secondary reinforcement in the form of fibre is added to concrete, which provides three dimensional random reinforcement in the entire mass of concrete. Reinforced concrete beams of size 0.1 m X 0.15 m and length 1m have been cast using M 35 grade of concrete. The beams after curing process were subjected to corrosion process by impressing an external Direct Current (Galvanostatic Method) for a period of 15 days under stressed and unstressed conditions. The corroded beams were tested by applying two point loads to determine the ultimate load carrying capacity and cracking pattern and the results of specimens were compared with that of the companion specimens. Gravimetric method is used to quantify corrosion that has occurred.

A Study on Cement-Based Composite Containing Polypropylene Fibers and Finely Ground Glass Exposed to Elevated Temperatures

High strength concrete has been used in situations where it may be exposed to elevated temperatures. Numerous authors have shown the significant contribution of polypropylene fiber to the spalling resistance of high strength concrete. When cement-based composite that reinforced by polypropylene fibers heated up to 170 °C, polypropylene fibers readily melt and volatilize, creating additional porosity and small channels in to the matrix that cause the poor structure and low strength. This investigation develops on the mechanical properties of mortar incorporating polypropylene fibers exposed to high temperature. Also effects of different pozzolans on strength behaviour of samples at elevated temperature have been studied. To reach this purpose, the specimens were produced by partial replacement of cement with finely ground glass, silica fume and rice husk ash as high reactive pozzolans. The amount of this replacement was 10% by weight of cement to find the effects of pozzolans as a partial replacement of cement on the mechanical properties of mortars. In this way, lots of mixtures with 0%, 0.5%, 1% and 1.5% of polypropylene fibers were cast and tested for compressive and flexural strength, accordance to ASTM standard. After that specimens being heated to temperatures of 300, 600 °C, respectively, the mechanical properties of heated samples were tested. Mechanical tests showed significant reduction in compressive strength which could be due to polypropylene fiber melting. Also pozzolans improve the mechanical properties of sampels.