Materiais Compsitos Aplicados Industria da

Construo Civil

Dr. Flvio de Andrade Silva

Departamento de Engenharia Civil

Pontifcia Universidade Catlica do Rio de Janeiro (PUC-Rio)
Rio de Janeiro Brasil
fsilva@puc-rio.br

Aula 1 Estrutura dos Materiais Compsitos Cimentcios

CIV 2197

www.civ.puc-rio.br
What is this course about?

Designed to help relate a materials microstructure to its

properties.
Infrastructural materials are often composites (portland
cement concrete, asphalt concrete, soils, geotextiles, fiber
reinforced composites).
Some RANDOM and HETEROGENEOUS, some
ORDERED.

2
Course outline

Course divided into 2 parts for logistical ease:

Part I: Microstructure of random and heterogeneous

materials (formation, characterization, interaction, fiber-
matrix interface)
Part II: Mechanics of infrastructural composites (fracture,
toughening mechanisms, Apllications, sustainability)

3
Construction Products:
Temporal, Spatial, and Scientific Span
Disciplines

Engineering
Chemistry
Biology
Mechanics
Computational modeling
Manufacturing processes
Sustainable development
Time
Nanometers - kilometers
scale
(1x10-8 to 1x103 metros)
hydration early age serviceability Long term
Performance
Seconds to centuries

Length (1 to 3x1010 seconds))

scale

4
Multi-Scale approach

Standards Performance
Durability
New technologies
Real scale tests
Structure
Durability, early ages and long term
properties, mechanical properties,
numerical modeling, standards, retrofit.

Processing Properties
Materials characterization
New materials, new processing
methodologies for cementitious
composites.

5
Social demands

Safe and comfortable housing;

Mitigation of natural disasters;
Fire, flooding, earthquakes and tsunamis.
Functional infrastructure for the economic and sustainable
development.

6
Composite Materials - Introduction

2 or more phases in a
macroscopic scale
Mechanical performance and
properties superior to those of the
independent phases
Relative volumes or fractions of
phases important
Shape, orientation, location of
phases

7
Composite Materials - Introduction
Definition: a material
composed of 2 or more
constituents
Reinforcement phase (e.g.,
Fibers)
Binder phase (e.g., compliant
matrix)

Advantages
High strength and stiffness
Low weight ratio
Material can be designed in
addition to the structure
Can manufacture structures and
eliminate joints

8
Composites Applications
Transportation: Ground, air,
marine, space
Military: armor, weapons,
containers
Sporting goods: golf, tennis,
fishing, helmets, ski/snow
boards
Building materials: pipes,
beams, panels, bridges,
roofing, decking, furniture etc.
Medical: braces, body moving
aids
Electrical & electronics: circuit
boards, junction boxes

9
Composites Applications
Kevlar reinforcement
Turbine

Airplane turbine
Problems: fatigue, corrosion,
density, temperature.

10
Types of Composite Materials

MMCs CMCs PMCs

Metal Matrix Composites Ceramic Matrix Comps. Polymer Matrix Comps

11
Types of Composite Materials
There are five basic types of composite materials: Fiber, particle, flake, laminar or
layered and filled composites.

Daniel & Ishai,

Engineering
Mechanics of
Composite
Materials

12
Types of Composite Materials

13
Types of Composite Materials

Particles suspended in a matrix

Any shape, size, configuration for
the particles

14
Types of Composite Materials

15
Types of Composite Materials

16
Types of Composite Materials
3D Visualization of
Pores and Inclusions

Pores

Inclusions

17
Types of Composite Materials

Inclusion Pore

18
Material Properties

Steel: density (Fe) = 7.87 g/cc; TS=0.380 GPa; Modulus=207 GPa

Al: density=2.71 g/cc; TS=0.035 GPa; Modulus=69 GPa

19
Matrix

The continuous phase that supports, separates, protects the

fiber/particle
Enables load transfer and redistribution
Brittle, ductile, elastic or plastic
Linear or non linear
Matrix must flow around the reinforcement during
processing
Lower density, stiffness and strength than the reinforcement
(not a requirement)

20
Composites

Strong reinforcement
Improve ductility
Brittle matrix
Stop/arrest crack propagation
Improved volume stability
Particulates in a matrix (aggregates in cement paste matrix)
Reduced cost
Cheaper particulates/fillers added

21
Composites

22
Strong fibers, weak matrix

23
Improving toughness

24
Homogeneous and Heterogenous materials

A material that is homogeneous is uniform in

composition or character (the properties are
independent of position in the body); one that is
heterogeneous is distinctly non-uniform in one of
these qualities (the properties depend on position
in the body).

25
Heterogenous materials

Synthetic Natural
Fiber composites Soil
Concrete (portland Sandstone
cement concrete/asphalt Granular media
concrete) Earths crust
Cellular solids Wood
Colloids Bone
Gels Blood
Emulsions Tissue
Cells

26
Mechanical Behavior - Introduction
Isotropic: material properties that are the same in every direction at a
point in the body.

Orthotropic: material properties that are different in three mutually

perpendicular directions at a point in the body.

Anisotropic: material properties that are different in all directions at a

point in the body.

27
Mechanical Behavior - Introduction

Micromechanics: study of composite material behavior

wherein the interaction of the constituent materials is
examined on a microscopic scale to determine their effect
on the properties of the composite material.

Macromechanics: study of composite material behavior

wherein the material is presumed homogeneous and the
effects of the constituent materials are detected only as
averaged apparent macroscopic properties of the composite
material.

28
Concrete: a complex composite material

29
Volumetric instability

Particulates of different
sizes added for
volumetric stability
Cement paste in
concrete is not stable

30
The question of scale

31
Cost reduction

32
What is Portland Cement ?

Raw material: Limestone (CaCO3) and Clay materials (SiO2)

+ grinding processes with temperature

33
Hydration mechanisms

Allen et al. 2007

H.M. Jennings, 1981
34
Hydration mechanisms
Structural models of C-S-H

Powers Feldman e
(1960) Sereda
(1970)

35
Hydration mechanisms

coloidal model or CM-II (H.M. Jennings)

Intraglobular pores Large gell pores

36
Hydration mechanisms

Calcium hydroxide:

37
Hydration mechanisms

The reaction of C3A with water takes place very fast

generating a high amount of heat.
Gypsum (CSH2 or Ca[SO4]2H2O) is added to the cement to
control the C3A hydration.

Ettringite (Aft) C6AS3H32

38
Hydration mechanisms

Monosulfate (Afm) C4ASH12

39
Hydration mechanisms

40
Hydration mechanisms
Heat of hydration:
4 4
Class G cement (LabEst) Class G cement (HB)
Class G cement (HB) 9.78 h
9.78 h Microsilica slurry 0.5%
Microsilica slurry 1.0%
3 3

2 2

Heat flow (mW/g) 1 1

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Time (hours) Time (hours)
4 4
Class G cement (HB)
9.02 h Nanosilica 0.25% 9.02 h Class G cement (HB)
Nanosilica 0.5% Nanocellulose 0.25%
3 Nanocellualose 0.50%

2 2

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Time (hours) Time (hours)

41
Hydration mechanisms

42
Hydration mechanisms

0.8 Degree of hydration

0.6

0.4

0.2

0
1 10 100 1000 10000 100000

E. Koenders, TU Delft Age (hours)

43
The concrete microstructure

+ cement =
paste

44
The concrete microstructure

45
The concrete microstructure

Nemati, Monteiro and Scrivener, Analysis of Compressive

Stress-Induced Cracks in Concrete. ACI Materials Journal

46
Dimensional stability - Shrinkage

47
Dimensional stability - Shrinkage

Cracks occur due to a high evaporation rate at the concrete

surface and to the development of capillary pressures.

48
Dimensional stability - Shrinkage

49
Shrinkage

50
Dimensional stability thermal Shrinkage

Elevated temperatures
During hydration

Cooling of the
external surface and
cracking restriction

51
 Fiber reinforced concrete

Multiple
cracking
pc
Tensile stress

cc

pc

Single crack
formation
Matrix

strain Crack opening

52
Fiber reinforced concrete

Fiber Matrix

Interface

Composite

Fiber

Strain Hardening or Strain Softening

Deflection Hardening or Deflection Softening Crack
400 m

53
 Cracking mechanisms

(a) (b) max

max frc

debonded Crack initiation

(c.1) (c.2) dyn

frc

debonded debonded

Crack propagation
F.A. Silva, B. Mobasher, C. Soranakom and R.D. Toledo Filho. Effect of fiber shape and morphology on interfacial bond and cracking behaviors
of sisal fiber cement based composites. Cement and Concrete Composites, (2011) 33 814-823.

54
 Cracking mechanisms
P
L microcrack

Stress
Bridging Fibers
Fiber
L

P bridged macrocrack
Matrix microcracks,
= L or pores
P
= P/A L Crack Width,
Stress-Crack Transverse ply Delamination
width relationship cracking cracks Intact Fibers

Strain Softening Behavior Stress

L

P
= L/L
= P/A
Avg Stress- Smeared
Strain Relationship

Strain hardening Behavior Matrix microcracks, Crack Width,

Bridging Fibers
or pores

55
Reinforcement

Reinforcement types: discrete

Carbon PVA
glass

Steel fibers Polipropylene Kevlar Natural fibers

56
Shrinkage
Evaporation
Autogenous shrinkage
Shrinkageage

Vaysburd (2006)

adsorbed
water

57
Pre-cast concrete Cementitious grouts

58
Concrete jaquet reinforced with fibers

59
Shotcrete

60
Hybrid reinforcement

61
Hybrid reinforcement

62
Hybrid reinforcement

63
Long term behavior - creep

64
Long term behavior - creep

65
Hybridization of reinforcement

9,5mm, spacing =10cm 9,5mm, spacing = 12cm

both directions (top and bottom). + 30 kg/m3 of steel fibers.

Explosive C4 (13.6kg)
Position: 2m
Specimen: 1.2m x 1.2m x 0.15m

66
Cement paste for oil well applications

67
Nano - reinforcement
Carbon nanotube

Amorphous carbon

1m

Use of nano silica, nano clay and nano reinforcement

68
 Smart Materials
Monitor the strain, stress, damage (corrosion) and temperature of a concrete
structure .
Measurement of electrical and di electrical parameters such as resistance and
capacitance in multiple frequencies.
The concrete can contain, for example, carbon fibers which are electrally
conductive the concrete can become a sensor and will measure the
changes in electrical resistance.

Wen and Chung, 2007

69
Multi Scale Reinforcement

100 m

200 m

70
Self-Healing
Sisal

10 m

Twisted steel

2mm

71
SHCC Strain Hardening Cementitious
Composites (PVA fiber)

PVA-fibres SAP-Particle

SHCC after mixing

72
SHCC Strain Hardening Cementitious
Composites (PVA fiber)

73
SHCC Strain Hardening Cementitious
Composites (PVA fiber)

74
SHCC Strain Hardening Cementitious
Composites (PVA fiber)
Aplicaes: Reforo de Alvenaria

triplet specimen (without strengthening layer)

spraying of a strengthening layer with a thickness of 10 mm

75
SHCC Strain Hardening Cementitious
Composites (PVA fiber)

20
F

Load F [kN] 15

10

with strengthening layer

5

without strengthening layer

0
0.0
0,0 0.5
0,5 1.0
1,0 1.5
1,5 2.0
2,0 2.5
2,5
Displacement [mm]

76
Continuous reinforcement textile reinforced
concrete (TRC)

Fabric
Yarn arrangement(yarns)
(bi-axial, multi-axial)

yarn
Formed by several
fillaments

Fillament
( 12-20 m)

77
Textile Reinforced Concrete

Fabric + Micro-Concrete Textile reinforced concrete

Alkali resistant glass High consume of Small thickness
carbon cement High performance
polymer Use of sand
Natural fibers

Fabric production Micro-concrete Processing

78
Textile Reinforced Concrete

3D Fabric

79
Fabric manufacturing

80
Mechanical behavior

81
Mechanical behavior
12
Control
10 10 Kg/m3
20 Kg/m3
Age = 28 Days
8
W/C = 0.4

Load, KN
HP12 AR Glass fibers
6
Vf = 20 Kg/m3
4
V f = 10 Kg/m3
2
Control

0
0 0.2 0.4 0.6
CMOD, mm

82
Mechanical behavior

83
Mechanical behavior

84
Mechanical behavior

2 carbon layers

F = 15kN = 1529 kg

Car weight = 1300 kgg

85
Mechanical behavior

Hybridization of
fibers

Arresting of Bridging of
micro-crack micro-crack

crack

short glass
fibers

20 m

short fibres bridging micro cracks

86
Mechanical behavior

Arresting of
micro-crack

Bridging of
micro-crack

embedding length
orientation
bonding with matrix

87
Interface
Yarn with no impregnation Yarn impregnated with polymer

Polymer
impregnation

Bond quality Bond quality

Increased bond between fillaments

Higher resistance
Fiber protection

Higher durability

Cross section micrograph of a yarn

88
Durability
28 days 360 days

28 days 360 days

89
Dynamic Behavior of structures

90
 Dynamic tests
25
mechanic 0.1 s-1
0.01 s-1
al clamps V
20 0.001 s-1
0.0001 s-1

Stress [MPa]
15 IV

I & II

10 III

5 BOP
+

BOP-

0
0 0.01 0.02 0.03 0.04 0.05
Strain [mm/mm]
30
TRC 5s-1
TRC 50s-1
TRC+Short fibres 5s-1
TRC+Short fibres 50s-1

20
Stress [MPa]

10

0
0 0.02 0.04 0.06 0.08
Strain [mm/mm]
F.A. Silva, M. Butler,V. Mechtcherine, D. Zhu, B. Mobasher. Strain rate effect on the tensile behaviour of textile-reinforced concrete
under static and dynamic loading. Materials Science & Engineering A (2011) 528 1727-1734.

91
 Dynamic testsPVA SHCC Systems
6
0.00001 s-1
0.0001 s-1
0.001 s-1
Adaptor to 0.01 s-1

Load Cell
4

Stress [MPa]
2

Specimen

0
LVDT 0 1 2 3
(fixed on the front Strain [%]
16
and back sides)
10 s-1
25 s-1
12 50 s-1
Fast Glue
Stress [MPa]

Steel Ring
8
Circular
Steel Plate
Adaptor to 4
Hydraulic jaw

0
0 1 2 3 4
Strain [%]
V. Mechtcherine, F.A. Silva, M. Butler, D. Zhu, B. Mobasher, S-L Gao,E Mder. Behaviour of Strain-Hardening Cement-Based
Composites Under High Strain Rates. Journal of Advanced Concrete Technology (2011) 9 51-62.

92
Use of Digital Image correlation (DIC)

Shear
Uniform lag Localization

T = 0.4 ms (a)

T = 0.3 ms

T = 0.2 ms
0.12
0.08
0.04 T = 0.1 ms
0
-20 -10 0 10 20 30
Axial Location, mm

93
 Influence of Temperature

Solution: use of mineral coating ?

Production technique suggested to limit the pullout

of yarns at the ends of the specimen

94
Refractory concrete Basalt fabrics

(a) (b) (c)

95
Refractory concrete Basalt fabrics

96
Refractory concrete Basalt fabrics

97
Applications Textile Reinforced Concrete

Schweinfurt, Germany

98
Applications Textile Reinforced Concrete

99
Applications Textile Reinforced Concrete

100
Applications Textile Reinforced Concrete

101
Applications Textile Reinforced Concrete

102
Applications Textile Reinforced Concrete

103
Applications Textile Reinforced Concrete

104
Applications Textile Reinforced Concrete

Surface preparation: sand blast

Application in layers
Micro-concrete
Fabric
Last layer of micro-concrete

Fabric
Micro concrete
Interface treatment

Rebar

105
Applications Textile Reinforced Concrete

106
Applications Textile Reinforced Concrete

Bridge designed with TRC in Kempten (Germany),

Span: 17 meters

107
Applications Textile Reinforced Concrete
Fabrication process

108
Exterior walls

109
Tubes
Plastic tubes Concrete tubes

110
Tubes
Advantages of TRC

Weight redutcion
high resistance to tensile load and high
ductility
High resistance to impact loading.

Applications

- Pipes under pressure(water, sewage, gas)

111
Tubes
Production technology

112
Furniture

113
 The use of natural fibers as reinforcement

Arch fibers

Structural fibers
600 m

F.A. Silva, N. Chawla, and R.D. Toledo Filho, Mechanical behavior of natural sisal fibers, Journal of Biobased
Materials and Bioenergy (2010) 4 106-113.

114
Microstructure of natural fibers - Sisal

ML
Tertiary
Conducting tissue 200 m Primary wall
wall
Arch fiber 10 m
Secondary
Lumen wall
Lignin
3 m
Tertiary Fibrillae
Wall
S2
200 m S1
Hemicellulose
Structural fiber Primary
Wall

115
Mechanical testing system for fibers

Force resolution 0.001 N

Aluminum foil Displacement resolution - 0.1 m
DC linear motor functions as a
force generator within the actuator
Fiber
Grip
assembly.
The actuator incorporates an air-
film bearing for near friction-free
operation.

116
Mechanical behavior
0.1

Displacement/Force (mm/N)
0.08

Contour line
0.06

200 m
0.04

t 1
= l+c 0.02
F EA
1
= 0.0015
EA

C = 0.0058792

t total displacement 0
0 5 10 15 20 25 30 35
F force
E Youngs Modulus Gage Length (mm)
A fiber cross-sectional area
fiber length
c machine compliance

117
 Mechanical behavior

500
Corrected for compliance

400 Delamination of
primary cell wall
Stress (MPa)

Raw data
300 Delamination of
adjacent fiber- cells
200

100
E = 19 GPa
0
0 0.005 0.01 0.015 0.02 0.025 20 m
Strain

F.A. Silva, N. Chawla, and R.D. Toledo Filho, Tensile behavior of high performance natural (sisal) fibers.
Composites Science and Technology, (2008) 68 3438-3443.

118
Cement based composites reinforced with natural
fibers
5
M0
0 M1

-5
OPC matrix
-10

Mass loss (%)

T0
-15
-20 Tf
-25
5 layers of -30 M0
fibers -35 CH free Matrix M1
-40
0 200 400 600 800 1000
Temperature (C)

Fiber Layer

Matrix

F. A. Silva et al. Physical and mechanical properties of durable sisal fiber cement composites. Construction &
Building Materials, (2010) 24 777-785.

119
 Mechanical Behavior
Multiple Image Analysis
crack
formation

Raw Binary Crack

image image spacing
measurement

F.A. Silva, B. Mobasher and R.D. Toledo Filho, Cracking mechanisms in durable sisal fiber reinforced cement
composites, Cement and Concrete Composites (2009) 31 721-730.

120
 Mechanical Behavior
16 160

Mean Crack Spacing, <CS>, mm

I & II
Cracks
Crack Spacing
Tensile Stress, MPa

12 120
IV

V
8 III 80 Multiple
crack
200 m
formation

4 40
Cracks
BOP+
BOP-

0 0
0 0.004 0.008 0.012 0.016
Strain, mm/mm UTS = 12 MPa
Youngs Modulus = 34 GPa

121
 Mechanical Behavior high speed tensile test
Piezoeletric 6000
load wahser 1000

4000 800
t = 20 ms
Sample

Displacement, mm

Velocity, mm/s
2000 0

Force, N
400
0
Force
Displacement -1000
Slack adaptor Velocity
High intensity lamps -2000
V = 1180 mm/s
0
-4000 -2000
-80 -40 0 40 80 120 160 200
Time, ms

Dynamic Strain rate = 25 s-1

Quasi Static Strain rate = 5.5 x 10-6s-1
F.A. Silva, D. Zhu, B. Mobasher, C. Soranakom and R.D. Toledo Filho, High speed tensile behavior of sisal fiber
cement composites, Materials Science and Engineering A (2010) 527 544-552.

122
Mechanical Behavior high speed tensile test
16

Dynamic
Static DIC Method
12
Tensile Stress, MPa

& = 24.6s 1
8

& = 5.5x106 s 1
0
0 0.2 0.4 0.6 0.8
Strain, mm/mm

BOP+ increased from 5.94 to 8.06MPa.

Dynamic Amplification Factor of 1.26.
Toughness at ultimate strength from static tests 8.27 kJ/m2
Toughness at ultimate strength from dynamic tests 45.5 kJ/m2

123
Mechanical Behavior impact loading

Drop Heights:
Piezoeletric load Load cell
washer
h = 101.6 mm
Loading head (4 in)

h = 152.4 mm
Arm level (6 in)
Phantom camera

Specimen h = 203 mm
(8 in)

LVDT
Load cell

124
 Comportamento Dinmico - Impacto
20

h = 101.6 mm
15
Stress, MPa

10
h = 152.4 mm

5 h = 203.2 mm

0
0 5 10 15 20 25
h = 152.4 mm (6 in)
Deflection, mm

F.A. Silva, D. Zhu, B. Mobasher and R.D. Toledo Filho, Impact behavior of sisal fiber cement composites
under flexural load, ACI Materials Journal (2011) 108 168-177.

125
 Comparison with other composite systems
Deflection, in
0 0.2 0.4 0.6 0.8
30 Glass h = 2 in (50.8 mm)
Glass h = 4 in (101.6 mm) 4
Sisal h = 4 in (101.6 mm)
Sisal h = 6 in (152.4 mm)
Stress, MPa

Stress, ksi
20

2
10
1

0 0
0 3 6 9 12 15 18 21
Deflection, mm
Glass Fabric (6 layers, Vf = 4% )
126
Natural textile reinforcement Jute fabric

127
Natural textile reinforcement Jute fabric
Each yarn is composed
by 141 single filaments

Textile type: plain weave

2.7 yarns/cm (weft)

Fineness:

Filament = 0.11tex*
Yarn = 15.82 tex*

3.5 yarns/cm (warp)

*Mass in g of 1 km
- each warp yarn interlaces with each weft yarn
yarn or filament
- least expensive to produce
128
Natural textile reinforcement Jute fabric

Melhorar a adeso fibra-matriz com o uso de um co-polmero

(Styrol-Butadien)

10 min 50 min

129
Natural textile reinforcement Jute fabric

Non-impregnated Impregnated

130
Interface

131
Interface
Uncoated fiber:

132
Interface
Coated fiber:

133
Interface

5 mm sem tratamento
5 mm com tratamento

134
Natural textile reinforcement Jute fabric

Matrix
Non-activated fillaments

Non impregnated Bond Impregnated with Bond

polymerin Beton

135
Natural textile reinforcement Jute fabric
Fabric

Matrix

Formwork

1, 3 and 5 fabric layers

136
Natural textile reinforcement Jute fabric

137
Natural textile reinforcement Jute fabric

Matrix 1 Layer 3 Layers 5 Layers

138
Natural textile reinforcement Jute fabric

5 Layers 5 Layers 5 Layers

Matrix Uncoated coated for coated for
10min 50min

139
Natural textile reinforcement Jute fabric

140
Conclusions
Cement based materials present a complex hydration mechanism
- Due to dimensional instability it may crack when the structural element is restrained.

Cement based materials can be reinforced with fibers in different

scales.
- Fiber reinforcement can control crack opening increasing ductility, strength and durability.

Textile reinforced concrete is an alternative material for the

construction industry.
- Its light, resistant and has a high strain capacity.

Reinforcement hybridization can be an alternative for the use of

rebars.

141