Carbon fiber reinforced concrete (Carbocrete)

 What is Carbocrete? History of carbon fibers  Manufacturing of carbon fibers  Carbon fibers in construction  Carbon fibers vs...  It is a type of concrete that is reinforced with

Aly

Attia

Ihab Khalil

Fathy Abdel Halim

MohamedMubarak

Presented to: Dr Mohamed Nagib Abou-Zeid

 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

 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

What is Carbocrete?

Carbocrete http://www.haute-innovation.com

 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

History of Carbon Fibers

Thomas Edison www.biography.com

Filament en.wikipedia.org

 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

History of Carbon Fibers (Cont’d)

Carbon fiber aircraft propeller

pics1.this-pic.com

Manufacturing of Carbon

Fibers

 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

Petroleum coal

www.c-chem.co.jp

PAN

www.c-chem.co.jp

 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

Manufacturing of Carbon Fibers

(Cont’d)

Manufacturing of Carbon Fibers

(Cont’d)

PAN Manufacturing Process www.arrhenius.ucsd.edu

Carbon Fiber in Construction

 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

http://www.carbonwrapsolutions.com www.sglgroup.com

Carbon Fibers vs Steel

 Up to 75% lighter

 More durable/corrosion-free

 5 times higher tensile strength

 2 times higher stiffness

 Higher temperature tolerance

Comparison of Fiber Strengths www.innovationskraftwerk.de

Carbon Fibers vs Steel (Cont’d)

Comparison Between Carbon Fibers and Steel Fibers www.innovationskraftwerk.de

Carbocrete Mixing Method

 Methods:

 Dry mix

 Wet mix

Mixing Methods http://wings.buffalo.edu

Carbocrete Mix Design

Mix Design For different CF sizes http://wings.buffalo.edu

 Compressive Strength Test

 Flexural Strength Test

 Slump Test

Testing

Key Properties of Carbocrete

Properties of Carbocete www.sglgroup.com

Advantages & Disadvantages

 Less materials needed for

maintenance and construction

High thermal conductivity

 High HVAC consumption

 More creative architectural design

High abrasion resistance:

 Suitable for highway construction

Low coefficient of thermal expansion

 High fire resistance

Economic Aspects

www.toray.com

Economic Aspects (Cont’d)

www.utsi.edu

 Limited applications

 In 2012, SGL Group launched a competition among

innovative engineers to answer the question "What can I make from carbon concrete?„

Applications (Cont’d)

 Carbocrete Balcony

www.sglgroup.com

Applications (Cont’d)

www.sglgroup.com

Applications (Cont’d)

www.sglgroup.com

Applications (Cont’d)

www.sglgroup.com

Applications (Cont’d)

 Carbocrete residential/office buildings

www.sglgroup.com

Applications (Cont’d)

 Video:

 http://www.youtube.com/watch?v=Ux1yIpGO7p8

design

very high loads

Thank you