FOR ORTA Macro Synthetic Fibers Replacement For Rebar Wire mesh - PowerPoint PPT Presentation

FOR ORTA Macro Synthetic Fibers Replacement For Rebar Wire mesh Steel Fiber STRONG AS STEEL

Presentation Outline  General Properties  Installation  Certifications  Applications  Feasibility Study  Test Results  Sample Projects

Reasons to Use FORTA  FORTA Eliminates Placing Errors  FORTA Provides Stronger Concrete Section  FORTA Allows the Concrete to Absorb More Energy  FORTA has Excellent Concrete Control Properties  FORTA is Safer, Discontinuous Reinforcement System  FORTA Helps Increase Worksite Safety  FORTA Significantly Reduces Construction Time  FORTA Reduces Reinforcing Costs by at least 50%

Data Sheet Materials Virgin Copolymer/Polypropylene Form Monofilament/Fibrillated Fiber System Color Gray Length 54 mm (2.25’’) Tensile Strength 570-660 MPa Specific Gravity 0.91 Absorption Nil Acid/Alkali Resistance Excellent Dosage Rate 1-4.5 Kg/m3

What Does FORTA Fiber Do? FORTA is used to:  Reduce plastic and hardened concrete shrinkage  Improve impact strength  Increase fatigue resistance  Increase concrete toughness  Increase concrete Durability

What is the mechanism?

What is the mechanism? FORTA is a color blended macrosynthetic fiber consisting of a twisted bundle non-fibrillating monofilament and a fibrillating network fiber, yielding a high-performance concrete reinforcement system. This extra heavy-duty macrosynthetic fiber offers maximum long-term durability, structural enhancements, and effective secondary/temperature crack control by incorporating a truly unique synergistic fiber system of long length design.

Installation Recommended dosage rate of FORTA fiber is 1 - 4.5 Kg/m3 added directly to the concrete mixing system during, or after, the batching of the other ingredients and mixed for usually 4-5 minutes. FORTA fibers can be added to concrete truck mixer on site, too.

FORTA Certifications FORTA Macrosynthetic fibers are in copliance with:  ACI 360R-10  ASTM C1116  ASTM C 1399  ASTM C1609  ASTM C1018  ASTM D7508  CE Certification  American Health Report  TS EN 14889-2/2006  JCI SF4

FORTA Applications  Slab on Metal Deck  Slab on Grade  Shotcrete  Precast Products  Concrete Pavements  Bridge Decks

Slab On Metal Deck FORTA fibers are used to eliminate rebar or wire mesh

Slab On Grade FORTA fibers are used to eliminate rebar or wire mesh

Shotcrete

Precast

Pavements

Feasibility Study 1- Slab on Metal Deck Comparing total costs of slab Concrete reinforcement using Rebars (ɸ 8 @ 30cm) and FORTA Fiber (1.65 Kg/m3) : Concrete Reinforced With Steel Bars ( Φ 8 @ 30 cm) Bar weight (Kg/m 2 ) 2.65 Price of Steel Bar (USD/Kg) 0.72 Costs of performance and labor (USD/Kg) 0.28 Total Cost of Using Steel bars (USD/m 2 ) 2.65 FORTA Reinforced Concrete (6 cm thickness) FORTA FERRO Dosage (Kg/m 2 ) 0.15 Price of FORTA FERRO Fiber (USD/Kg) 11.00 Total Cost of Using FORTA (USD/m 2 ) 1.65

Feasibility Study So by using FORTA FERRO Fibers we can achieve to at least 1.0 $/m 2 Saving in construction costs. Beside economical advantages FORTA provides:  Reduced labor  Reduction of Cracking  Enhancements to ductility, toughness and impact resistance  Elimination of the potential for reinforcement corrosion

Feasibility Study 2- Slab on Grade Comparing total costs of slab Concrete reinforcement using Rebars (ɸ 8 @ 15 cm) and FORTA Fiber (1.8 Kg/m3) : Concrete Reinforced With Steel Bars ( Φ 8 @ 15 cm) Bar weight (Kg/m 2 ) 5.3 Price of Steel Bar (USD/Kg) 0.72 Costs of performance and labor (USD/Kg) 0.28 Total Cost of Using Steel bars (USD/m 2 ) 5.30 FORTA Reinforced Concrete (15 cm thickness) FORTA FERRO Dosage (Kg/m 2 ) 0.27 Price of FORTA FERRO Fiber (USD/Kg) 11.00 Total Cost of Using FORTA (USD/m 2 ) 3.00

Feasibility Study So by using FORTA Fibers we can achieve to at least 2.30 $/m 2 Saving in construction costs. Beside economical advantages FORTA provides:  Reduced labor  Reduction of Cracking  Enhancements to ductility, toughness and impact resistance  Elimination of the potential for reinforcement corrosion

Test Results 1- Compressive Strength (ASTM C39) Compressive FORTA Fiber (Kg/m 3 ) Strength (MPa) 2.4 33.9 2.7 36.44 3.0 38.55 3.3 38.25 3.6 40.9 3.9 42.1 4.2 42.1 4.5 44.7 30% increase in compressive strength

Test Results 2- Impact Resistance (ACI 544) Number of Blows (First FORTA (Kg/m 3 ) Crack) 0 17 4.5 85 9.0 95 13.5 100 18.0 215 5 times more than plain concrete

Test Results 3- Shrinkage Crack Area FORTA (Kg/m 3 ) Reduction (%) 4.5 92 9.0 97 18.0 100

Test Results 4- Average Residual Strength (ASTM C1399) Avg. Residual FORTA (Kg/m 3 ) Strength (MPa) 0 0.18 4.5 2.25 9.0 3.23 13.5 3.25 18.0 4.62 10 times more than plain concrete

Test Results 5- Three Dimensional Performance When a crack occurs, the traditional rebars can not meet the shrinkage stresses occurred on the structural bearing points. FORTA provides the resistance with 3 dimension and increases the bending resistance on every part of the structure.

Test Results 6- Freezing and Thawing Resistance FORTA provides freezing and thawing resistance by stopping cracks to continue, holding the concrete together, preventing the impairment of the aggregate-cement matrix, holding the breakage of the concrete on the minimum level.

Test Results 7- Elastic Behavior The changes of the concrete is much limited since the concrete has a brittle behavior. The possibility of failure comes out even on the values under carrying capacity in consequence of the fatigue effect under the repeated loadings.

Test Results FORTA vs. Steel Fibers  In addition to concerns regarding corrosion and rising costs, steel fibers can be challenging to add, mix, and shoot at the elevated dosages (50 to 120 lbs./cu. yd.).  Ready-mix concrete producers often encounter difficulties in adding steel fibers in an even manner that will facilitate uniform distribution and minimize clumping and balling.  Steel fibers typically have little if any affect on the reduction of plastic shrinkage cracking, an area where FORTA synthetic fibers shine.

Test Results FORTA vs. Steel Fibers 1- Impact Fiber Dosage Number of Blows Fiber (Kg/m 3 ) (Ultimate Failure) Forta 2.7 300 Forta 3.6 425 Steel 24 175 Steel 30 225 FORTA has shown dramatic improvement to impact resistance as tested by the ACI Committee 544 Drop Hammer test. Most impressive is the fiber’s ability to allow for specimen integrity, even after first crack.

Test Results FORTA vs. Steel Fibers 2- Avg. Bending Resistance Fiber Avg. Bending Fiber Dosage Resistance (Kg/m 3 ) (MPa) Forta 2 3.63 Forta 4 3.79 Forta 6 4.11 Steel 20 3.63 Steel 30 4.06 1 Kg/m3 FORTA = 10 Kg/m3 Steel Fiber

Test Results FORTA vs. Steel Fibers 3- Tensile Strength Fiber Dosage Tensile Strength Fiber (Kg/m 3 ) (MPa) Forta Ferro 2 3.74 Forta Ferro 4 4.15 Forta Ferro 6 4.46 Steel 20 3.71 Steel 30 4.21 1 Kg/m3 FORTA = 10 Kg/m3 Steel Fiber

Test Results FORTA vs. Steel Fibers 4- Toughness The average test results related to the toughness value corresponding the deflection of 25mm have been demonstrated on the table. Dosage Toughness Fiber Type (Kg/m 3 ) (J) FORTA 2 600.3 STEEL 20 686.5 FORTA 4 896.1 STEEL 30 931.9 FORTA 6 1290.3 FORTA 8 1554.1 1 Kg/m3 FORTA = 10 Kg/m3 Steel Fiber

Test Results 1 Kg/m3 FORTA = 10 Kg/m3 Steel Fiber

 Slab Thickness : 20 cm  Total Area : 2700 m2 Slab on Metal Deck Sigma Thermal Corporation, Marietta, GA, 2011

 Slab thickness : 25 cm Terminal Island Salvage Yard, Island, CA, 2000

Slab on Grade FORTA Manufacturing Floor Slab, Grove city, PA, 2004

Precast Lanai Breakwater Core-Loc Dolos, Hawaii, 2007

Reduced Joint Slab on Ground MLK Humboldt Basin, Buffalo, NY, 2012

 Slab thickness : 6-10 cm  Total Area : 70000 m2 Slab on Grade Varyap Meridian Parking Lot, Istanbul, Turkey

 Slab thickness : 20-30 cm  Total Area : 100000 m2 Slab on Grade Samsun Port, Samsun, Turkey

 Total Area : 4500 m2 Tunnel Shotcrete Berraksu Hes, Trabzon, Turkey

Tunnel Shotcrete ADACAMI HEPP, RIZE, Turkey

 Tunnel Length : 5440m Tunnel Shotcrete Caykara,Trabzon, Turkey

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