Carbon fiber reinforced concrete (Carbocrete)


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Carbon fiber reinforced concrete (Carbocrete)

  1. 1. The American University In Cairo School Of Science And Engineering Department Of Construction and Architectural Engineering Presented to: Dr. Mohamed Nagib Abou-Zeid Aly Ihab Attia Khalil Fathy Abdel Halim Mohamed Mubarak
  2. 2.              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
  3. 3.  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. Carbocrete
  4. 4.  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. Thomas Edison Filament
  5. 5.  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. Carbon fiber aircraft propeller
  6. 6. 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 PAN Petroleum coal
  7. 7.  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.
  8. 8. PAN Manufacturing Process
  9. 9.  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.
  10. 10.  Up to 75% lighter  More durable/corrosion-free  5 times higher tensile strength  2 times higher stiffness  Higher temperature tolerance Comparison of Fiber Strengths
  11. 11. Comparison Between Carbon Fibers and Steel Fibers
  12. 12.  Methods:  Dry mix  Wet mix Mixing Methods
  13. 13. Mix Design For different CF sizes
  14. 14.  Compressive Strength Test  Flexural Strength Test  Slump Test
  15. 15. Properties of Carbocete
  16. 16. Advantages Disadvantages High tensile strength:  Smaller cross-sections  Earthquake resistance Expensive:  High initial cost Higher durability:  Corrosion-free  Less running cost Lack of knowledge:  Absence of codes  No implementations yet Eco-friendly:  Less materials needed for maintenance and construction. High thermal conductivity  High HVAC consumption Low weight:  Easy to handle Risk of lung cancer in the manufacturing phase High flexibility:  More creative architectural design High abrasion resistance:  Suitable for highway construction Low coefficient of thermal expansion  High fire resistance
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  19. 19.  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
  20. 20.  Carbocrete Balcony
  21. 21.  Shore protection seashells
  22. 22.  Carbocrete bicycle stands
  23. 23.  Carbocrete Z-shell
  24. 24.  Carbocrete residential/office buildings
  25. 25.  Video: 
  26. 26.  Carbocrete pushed the limits of creativity and flexibility in design  Made it possible to build unique structures that can withstand very high loads  Save maintenance costs on the long run
  27. 27.          e%20reinforced%20with%20up%20to%20vol%20of%20short%20ca rbon%20fibers.pdf