Technical Material Submittal

Transcription

1 Technical Material Submittal

2 Page 2 of 11 The design values and recommendations contained herein is considered representative of present production and believed to be reliable. They are based on international certifications and compliance reports as well as on the results of extensive research and testing. The data and values within this technical document are intended to provide the design engineer and planner with an understanding of mateen products. The information provided herein does not release the design engineer of his duties and responsibilities. It does not replace commonly accepted engineering rules and regulations. Limited reserves the right to make improvements in the product and process which may result in benefits and/or changes to some physical and mechanical properties

3 Page 3 of 11 Contents 1.0 Fibre Reinforced Composite Mateen Overview Product Description Reference Standards and Reports Standard Compliance Material Properties Data Bar Sizes, dimensions and weights Mechanical Properties Straight Bars Material Properties and Test Standards Bends Design Capability Durability Quality Control requirements for raw materials: Manufacturing Quality Control Handling and Storage Instructions Warranty... 10

4 Page 4 of Fibre Reinforced Composite Pultron s mateenbar TM is a composite material, made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components. One of the most common and well understood composites is glass fibre reinforced polymer (GFRP) composites. It consists of glass fibres (reinforcement) suspended in a resin system (matrix). It is used in many fields from aerospace to electronics, to produce high strength, light weight durable products that are manufactured through a variety of different processes. Mateenbar TM is manufactured using the pultrusion process where glass fibres are pulled through a resin bath and then through a heated die to cure. This process uniformly aligns the continuous glass fibres resulting in a high tensile strength bar. 2.0 Mateen Overview Product Diameters Lengths Purpose mateenbar TM 6-38mm 12m stock lengths Tensile reinforcement for Can be produced to order concrete structures mateenbend TM 8-25mm Standard bends and stirrups can be produced 1 Tensile reinforcement for concrete structures mateendowel TM 6-38mm 0.2-2m Expansion joint shear reinforcement mateenbolt TM 22, 25 and 32mm 1-12m Rock anchors for strata support and slope stabilisation 1. Please confirm dimensions with sales

5 Page 5 of Product Description Pultron s mateenbar TM is the latest generation of composite rebar to address the issues faced by traditional steel based reinforcement in concrete structures. Mateenbar TM : A composite material; ECR glass (reinforcement) and modified vinyl ester (matrix) Ribs are post ground into the bar and provide bonding characteristics similar to traditional reinforcement bars Mechanical properties are comparable to that of steel rebar Bars cannot be permanently deformed or bent; bends are manufactured to order Material Characteristic High Corrosion Resistance High Chemical Resistance Non-Conductive Non-Magnetic Low Thermal Conductivity Easily Cut Applications Marine environments, roading, bridges, infrastructure and applications requiring minimal concrete cover Industrial processing plants and agricultural facilities Smelters, rail signal and switches, substations MRI s, high tech laboratories, sensitive equipment rooms Thermal barriers in sandwich panels and joints temporary reinforcement in tunneling, soft eyes, strata support Properties Steel Rebar Stainless Steel mateenbar TM Rebar Tensile Strength (MPa) >900 Yield Strength (MPa) Does not yield Modulus of Elasticity (GPa) Density (g/cm 3 ) Thermal Conductivity (W/mK) <0.5 Transverse Coefficient of Thermal Expansion (1/K) 10 x x x 10-6 Magnetism Yes Minimal no

6 Page 6 of Reference Standards and Reports The references below should be referred to by the engineer regarding the application of mateenbar TM for concrete reinforcement. Additional information is available from for design assistance for specific applications References Titles ACI Building Code Requirements for Concrete (1995) American Concrete Institute, Farmington Hills, MI, USA ACI 440.3R-12 Guide Test Methods for Fiber-Reinforced Polymer (FRP) Composites for Reinforcing or Strengthening Concrete and Masonry Structures ACI Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials for Concrete Reinforcement ACI 440.1R-06 Guide for the Design and Construction of Concrete Reinforced with FRP Bars American Concrete Institute, Farmington Hills, MI, USA ACI Specification for Construction with Fiber-Reinforced Polymer Reinforcing Bars CSA S Specification for fibre-reinforced polymers CSA S Design and construction of building structures with fibre-reinforced polymers AASHTO GFRP - 1 American Association of State Highway and Transport Officials ISBN Standard Compliance Mateenbar TM meets and exceeds the requirements of Canadian Standard CSA S for a Grade III (High Strength and High Elastic Modulus) DI (High Durability) GFRP Rebar. Mateenbar TM meets and exceeds the requirements of American Concrete Institute ACI440. Mateenbar TM manufacturing facilities and production quality control system are certified to ISO 9001: Material Properties Data mateenbar TM 6.1 Bar Sizes, dimensions and weights Designated Imperial Size Designated Metric Size Core Diameter (mm) Outer Diameter (mm) Cross- Sectional Area (mm 2 ) * Nominal Cross- Sectional Area (mm 2 )** Weight (kg/m) 6 # # # # # # # # *Cross-sectional area is measured in accordance with CAN/CSA S806 Annex A **Do not use this area for calculations Other sizes are available upon request

7 Page 7 of Mechanical Properties Straight Bars Property Ultimate Tensile Load (Average), kn Ultimate Tensile Strength (Average), MPa Ultimate Tensile Load (Guaranteed), kn Ultimate Tensile Strength (Guaranteed), MPa Tensile Modulus of Elasticity (Guaranteed), GPa Ultimate Elongation (Guaranteed), % Transverse Shear Strength (Average), MPa Bond Strength at Failure (Average), MPa Bond-dependent Coefficient kb Material Properties and Test Standards Property Unit Values Test Standard Ultimate Tensile Strength (Average) MPa >930 ASTM D7205, ACI 440.3R-04, CAN/CSA S806 Annex C Ultimate Tensile Rupture Strain ACI Ultimate Elongation (Guaranteed) % ASTM D7205, ACI 440.3R-04, CAN/CSA S806 Annex C Tensile Modulus of Elasticity GPa >57 ASTM D7205, ACI 440.3R-04, CAN/CSA S806 Annex C Transverse Shear Strength (Average) MPa 180 ASTM D7617, ACI 440.3R-04 Flexural Strength MPa >900 ASTM D790 Flexural Modulus GPa >53 ASTM D790 Compressive Strength MPa >400 ASTM D695 Short Beam Shear Strength (Average) kn >80 ASTM D447 Bond Strength at Failure MPa ACI 440.3R-04 Bond-dependent Coefficient kb ACI 440.1R-06 Barcol Hardness >60 ASTM D2583 Glass Transition Temperature o C >100 ASTM D3418 Thermal Expansion Coefficient - Transverse 1 / o Cx10-6 <30 ASTM E831 Thermal Expansion Coefficient - Longitudinal 1 / o Cx10-6 <30 ASTM D 696 Volume Resistivity Ω.m x DIN Dielectric Strength kv/m 6000 ASTM D149 Fibre Content % >75 ASTM D2584 Moisture Uptake (24 hour) % <0.025 ASTM D570 at 50 o C Moisture Uptake at Saturation (Maximum) % <0.125 ASTM D570 at 50 o C Specific Gravity 2.16 CAN/CSA S806 Annex A Guaranteed Ultimate Tensile Strength: CSA S Classification Based on Tensile Strength. The tensile properties of 38mm mateenbar TM cannot be guaranteed due to inability to achieve a valid bar as per the requirements of ASTM D7205 and ACI440.3R- 04.

8 Page 8 of Bends Mateenbar TM cannot be bent on site and must be fabricated into the required shape at the mateenbar TM factory. Due to the differences in GFRP manufacturing processes compared to steel rebar bends, there are limitations in the shape and sizes of bends available. Mateenbend TM is significantly slower to fabricate than the steel rebar equivalent, please allow sufficient lead time in your schedule to avoid delays. Please contact Pultron to discuss your specific bends requirements and estimated lead times. Property / Diameter Unit Root diameter mm Nominal area mm Tensile strength (average) MPa Tensile strength (Guaranteed) 1 MPa Tensile modulus of elasticity GPa >57 >57 >57 >57 >57 > Design Capability Pultron manufactures and supplies only. Design detail is provided by contractor and/or consultants, however Pultron can assist in value engineering and design support. Please refer to the appropriate design guide for your project or jurisdiction, e.g. ACI 440.1R Guide for the Design and Construction of Concrete Reinforced with FRP Bars for guidance on the use of GFRP Bars such as mateenbar TM. Requirements: Do not substitute FRP reinforcing bars for steel or other supplier GFRP bars on an equal area basis, due to differences in material properties Design requirements on crack width, moment capacity and deflection with respect to material properties such as tensile strength, elastic modulus must be accounted for. Please consult with Pultron for structural design considerations In most cases, deflection will control design of concrete structures reinforced with FRP bars based on value of modulus of elasticity of FRP bars Stress under sustained load should be limited in accordance with the ACI 440.1R Section 8.4 Creep rupture and fatigue recommendations for GFRP bars A minimum overlap length of 40 diameters is recommended for straight bars.

9 Page 9 of Durability Property Value Test Method Moisture Uptake < 0.1% ISO , ASTM D 570 Resistance to alkaline environment After 6 months (typical): Tensile strength retention by 87% Elastic modulus retained by 100% Transverse shear strength retention by 92% Short beam shear strength retention by 100% Moisture absorption 0.4% Glass transition temperature retention by 100% ACI 440.3R-4 B.6 Test Conditions: ph: at 60 o C 9.0 Quality Control requirements for raw materials: Property Value Test Method / Comment Resin Type ACI Matrix Resins Epoxy vinyl ester resin Required for long term corrosion resistance and mechanical strength. Polyester resin not allowed for permanent structures in accordance Glass Type ACI Fibers Fillers ACI Fillers and additives ECR-glass Commercial Grade Inorganic Filler with ACI ECR Glass (ASTM D578) is essential due to long-term corrosion resistance and immunity to alkaline attack. E-Glass not allowed Commercial grade inorganic fillers only used < 20% by mass 10.0 Manufacturing Quality Control Mateenbar TM is a GFRP rebar manufactured from materials fully conforming to ACI Specification for Carbon and Glass Fibre-Reinforced Polymer Bar Materials for Concrete Reinforcement. Mateenbar TM is manufactured from materials sourced on long term supply contracts with internationally approved suppliers. Raw materials purchased on the spot market are not used in the manufacture of mateenbar TM. A test certificate with every shipment shall be supplied which contains: Test with every shipment Incoming resin Diameter Glass fibre content Test Method / Requirement Enthalpy of reaction and Glass transition temperature analysis by DSC prior processing Minimum of 1 per resin batch (may apply to more than one batch of dowel production) As measured from tolerance sheets at 2 hourly checks Fibre content > 75% by Volume

10 Page 10 of 11 Short Beam Shear Strength Glass transition temperature Surface Glass fibre content continuously monitored and manually confirmed every 2 hours Average and standard deviation derived from production tolerance sheets Short beam shear tests performed from each product stream every 2 hours Tg >= 100 o C. Minimum of 1 test every 10,000 meters. For production runs of less than 10,000 meters, one test per batch is considered That the surface is crack free, as per the two hourly tolerance sheet information 11.0 Handling and Storage Instructions Instructions Placement and Fastening Tolerances Splicing Ties Bending Cutting mateenbar TM Scrapes and cuts Storage Handling Comparison Notes Place mateenbar TM in accordance to CRSI Placing Reinforcing Bars, unless otherwise specified. Place mateenbar TM accurately in accordance with approved placing drawings, schedules, typical details and notes. Secure mateenbar TM in formwork to prevent displacement by concrete placement or workers. Fasten mateenbar TM with nylon ties (preferable), coated or stainless steel tie wire Do not exceed placing tolerances as per ACI117 Use lap splices Use coated tie wire, plastic or nylon cable ties (preferable) Mateenbar TM cannot be bent onsite Mateenbar TM can be cut in the field with a standard handsaw or small grinder or cutoff saw For long blade life time use diamond blades Nicks, scrapes, and cuts that do not exceed 5% of the depth of the bar are acceptable Beyond 5% we recommend replacement of the bar Mateenbar TM not used immediately should be kept on a pallet and covered with a tarp to avoid exposure to UV rays Mateenbar TM can be kept for an indefinite period of time without losing its performance Contamination with form releasing oil shall be avoided as this may reduce bonding with concrete Do not store in areas subject to high temperatures (>85 degrees Celsius) and avoid contact with chemical substances It is recommended that gloves are worn when handling mateenbar TM Mateenbar TM can be handled in the same way as steel equivalents in the field See also ACI 440.1R-06 Specification for Construction with Fibre-Reinforced Polymer Reinforcing Bars Warranty Mateenbar TM is sold subject to Pultron Composite s standard warranty and nothing herein shall expand or extend such warranty.

11 Page 11 of 11 Middle East Jebel Ali Free Zone PO Box Dubai United Arab Emirates Tel: Fax: mateen@mateenbar.com Ltd 342 Lytton Rd Gisborne PO Box 323 Gisborne 4040 New Zealand Tel: Fax: sales@pultron.com