Carbon Products By Nickunj Eximp ENTP Private Limited, Mumbai

Application of Polymer Composite Materials in Building & Construction

From NICKUNJ GROUP –Mumbai [email protected], [email protected] S.C.Mehta –Project Manager Tel +91-22-22190300 ext.335 ,Fax +91-22-22060415

mailto:[email protected],[email protected]

Designed for repair and strengthening of the building structures in order to eliminate the effects of concrete destruction and reinforcement corrosion due to long-term exposure to aggressive environmental factors during operation

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Application

At the design stage•Seismic retrofitting •Strength of structures enhancement while maintaining the consumption of materials•Strength enhancement under extreme loads•Increased service life of structures During construction and operation•Design errors elimination or performance of works (undersized cross-section of reinforcement, concrete strength does not meet project requirements, deviations from the project reinforcement)•Changes in the design concept of building elements, formation of openings •Carrying capacity of structures enhancement with an increase in design loads •Elimination of the sequences of damage to the supporting structures during the operation

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Fabric type

Parameters

Weave type Width, mmAreal weight,

g/m2

Q-ty of filaments

Fibre elongation at

break

Monolayer tape design thickness,

mm

E-Modulus, GPa

(fibre)

Tensile Strength,

Gpa(fibre)

Unidirectional carbon tapes

FibARM Tape - 200/300

Plain fabric 300 200 12К 1,8% 0,111 245 4,3


Plain fabric 300 230 12К 1,8% 0,128 245 4,3


Plain fabric 300 300 12К 1,8% 0,167 245 4,3


Plain fabric 300 350 12К 1,8% 0,194 245 4,3


Plain fabric 150 530 12К 1,8% 0,294 245 4,3


Plain fabric 300 530 12К 1,8% 0,294 245 4,3


Plain fabric 600 530 12К 1,8% 0,294 245 4,3

Bidirectional carbon tapes

FibARM Tape - 240/1200 twill

Twill 1200 240 3К 1,8% 0,066* 245 4,3


Twill 1200 300 6К 1,8% 0,083* 245 4,3


Twill 1200 450 12К 1,8% 0,125* 245 4,3

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Fabric type

Parameters


g/м2

Q-ty of filaments

Fibre elongation at break

Monolayer tape design

thickness, mm

E-Modulus, GPa

(fibre)

Tensile strength,

GPa(fibre)


FibARM Tape - 530/150 Plain fabric 150 530 12К 1,8% 0,294 245 4,3

Carbon Fabric Tape with width 150 mm specially designed for strengthening:•Ribbed floor slabs•T-beams of bridge spans with a small rib width•Beam elements of frame structures•Frames and small scale structures

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Fabric type

Parameters


g/m2

Q-ty of filaments

Fibre elongation at break


thickness, mm

E-Modulus, GPa

(fibre)

Tensile strength,

GPa(fibre)


FibARM Tape - 530/600 Plain fabric 600 530 12К 1,8% 0,294 245 4,3

Carbon Fabric Tape with width 600 mm specially designed for strengthening:•Columns and pylons•Wide band reinforcement of slabs•Structures with high requirements to seams•Concrete elements with a large-scale grid-cracking

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Fabric type

Parameters


g/m2

Q-ty of filaments

Fibre elongation at

break


thickness, mm

E-Modulus, GPa

(fibre)

Tensile strength,

GPa(fibre)


FibARM Spread Tape – 230/250

Spread tape 250 230 48К, 50K 1,8% 0,128 245 4,3


Spread tape 500 230 48K, 50K 1,8% 0,128 245 4,3


Spread tape 250 530 48K, 50K 1,8% 0,294 245 4,3


Spread tape 500 530 48K, 50K 1,8% 0,294 245 4,3

Carbon Fabric Spread Tape advantages:•Increased contact area•Adhesion enhancement•Quality of impregnation enhancement•Even distribution of reinforcing material in structural strengthening system•Resin consumption and total thickness of strengthening system reduction

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Color Component А: dark-grey, Component B, light-grey

Density 1.3 g/cm3 (mixed A and B components)

Mixing ratio Component A: Component B = 100 : 35 (by weight) Precise mixing proportions should be measured by means of scales.

Substrate and ambient temperature +10°С to +45°С

Pot life / open time At 10ºС 3 hours At 20ºС 2 hoursAt 30ºС 1 hour

Bond Strength Over 3.5 Mpa ((concrete break)

Shear Strength(7 days at 23ºС)

>14 MPa

General PurposeTwo-component epoxy based composition. Used as an impregnating system for FibARM reinforcement system on the base of carbon fiber tapes or as a structural adhesive for carbon fiber laminates to even surfaces.Advantages:•Designed specifically for FibARM Structural Strengthening System•High mechanical characteristics•High adhesion to different surfaces: concrete, metal, wood, masonry•Convenient for manual fabric impregnation•Suitable for fabrics with any areal weight•Primer not required

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Carbon fibre content, % 60 – 70

Number of monolayers 3-12

Tensile Strength, MPa 1300 - 2800

E-modulus, GPa 165-300

Width, mm 50-150

Thickness, mm 1.2 -1.4

Surface Grinded on one side

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Grid spacing, mm 50х50 30х30 10х18

Areal weight (dry grid), g/m²

150 230 530

Areal weight (grid with impregnation),

g/m²170 270 610

Grid thickness, mm 1-2

Width, m 0.3-1.2 Length, m 100

a) Separate mixing of A and B components with electric low speed mixer; b) Mixing A and B components with ratio 100:35 (A:B) by weight; c) Tapes cutting; d) Defatting and activation of tapes;e) Resin layer applying to concrete in amount 0.9 to 1.5 kg/m2;f) Dry fabric is applied to the coated substrate;g) The fabric is carefully rolled with impregnating roller strictly in the fiber directionh) A colored or cement coating is applied to the fabric surface

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a) b) c) d)

e) f) g) h)

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Enhanced time efficiency; Reduced labor costs (no need for heavy equipment); Work can be carried out without interruptions in construction or disruption of traffic; Reduced costs for maintenance; Increased time between repairs; Ability to correct design and construction errors; No additional weight to original structure

Strengthening with metal

profile

Strengthening with reinforced concrete frame

Strengthening with composite

materials

Bridge dimensions: length – 15.65m; width – 8.29m

Year of construction – 1950;

Moving load limitation - 20 tons

Defects:

Reinforcement exposed to surface corrosionAdditional layer of road dressing creates a non-project loadsAreas with concrete destruction and reinforcement exposingLongitudinal cracks (depths unspecified)Insufficient carrying capacity due to structure damage and new rated loads mismatch

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Cross-section

Section Section

Section

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Cost Items Sum, Rubles

Project 100 000,00

Materials 417 756,00

Works 238 455,00

Total:

Cost estimate incl. VAT 756 211,00

Cost Items Sum, Rubble

Project 100 000,00

Materials 649 823,00

Works 649 231,00

Total:

Cost estimate incl. VAT 1 399 054,00

Rated load Rated load value, tons

Design load before strengthening Н-13; НГ-60(Д) 48,00

Actual load before strengthening 20,00

Actual load after strengthening АК-14 82,23

Net cost calculation of repairing with Structural Strengthening System

Net cost calculation of repairing with metallic tension rods

Composites

Reconstruction

Repairing cracks over 1 mm width in masonry wall

wall

injector

30 mm notch

Carbon rod

crack

Strengthening of bearing zones layout

CrackWindow jumper

Crack

FibARM Carbon Tape 230/300

Wall

Window aperture

Note:Size depends on crack angle

Strengthening of an apartment house structures with composite materials:

- estimated cost of strengthening with carbon rods – 263,141 thousand rubles

- estimated cost of strengthening with carbon tapes – 765,432 thousand rubles

TOTAL: 1 028,573 thousand rubles

Strengthening of an apartment house structures with metal:

- estimated cost of strengthening with metallic reinforcement - 544,702 thousand rubles

- estimated cost of strengthening with metallic sheets – 1 048,641 thousand rubles

TOTAL: 1 593,343 thousand rubles

Economic effect – 564,770 thousand rubles

Strengthening with metal

Cost item Sum, RubbleReplacement

Materials 3 510 000,00Machinery 3 770 000,00Payment for labor 720 000,00TOTAL 6 244 800,00

Strengthening with metalMaterials 1 050 231,78Machinery 121 180,59Payment for labor 175 038,63TOTAL 1 346 451,00

Strengthening with composite materialsMaterials 359 979,75Machinery 41 536,13Payment for labor 59 996,63TOTAL 461 512,50

Economic effect compare vs. replacementStrengthening with metal 4 898 349,00

Strengthening with composite materials 5 783 287,50

Replacement Strengthening with metal

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Recommendations on calculation of reinforced structures with structural strengthening system using FibARM

polymer composites. Approved by Concrete and Reinforced Concrete Research Institute.

Guidance on reinforced structures strengthening with composite materials. Concrete and Reinforced Concrete

Research Institute, LLC Interaqua. М. 2006

Shilin A.A., etc., Structural reinforcement of reinforced concrete elements with composite materials – М.:JSC

Stroyizdat publishing house, 2007. – 184с.:illustr.

Regulation on reinforced structures maintenance of underground collectors for engineering networks. Moscow

2009. Approved by Moscollector, Moscow city government.

SNiP 2.05.03-84* “Bridges and pipes” Composite materials are allowed to be used in design of walking bridges

and during reconstruction and strengthening of bridges (excluding railroad bridges).

Prices on carbon materials by CJSC Prepreg-ACM are included by Regional Development Ministry into Federal

Book of Estimate Prices “Federal estimated price on materials and structures used in construction" (FCCTS 81-

01-2001-E5)

Set of rules “Strengthening of reinforced structures with composite materials”. Developed by JSC Triada-

Holding and Concrete and Reinforced Concrete Research Institute

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Technical Conditions 1916-005-61664530-2011 “Carbon unidirectional tapes for structural strengthening

systems”

Standard of organization 2256-002-2011 “FibARM® Structural strengthening system for repairing and

reinforcement of building structures”. Approved by Concrete and Reinforced Concrete Research Institute

Certificate of conformance of Technical Conditions for FibARM® Carbon Tape

Certificate of conformance of Standard of Organization for FibARM® Structural Strengthening System

Fire certificate for FibARM® Carbon Tape (flammability group– non-combustible, material danger class – KM0)

Fire certificate for FibARM® structural strengthening system without flame retardant coating (flammability

group G1)

Safety and health certificate for FibARM® Tape for building structures reinforcement

Safety and health certificate for FibARM® Tape for drinking water supply systems reinforcement

Technical Conditions № 2257-012-61664530-2012 “Two component epoxy composition FibARM Resin 230 for

FibARM® structural strengthening system impregnation”

Certificate of conformance of Technical Conditions for FibARM® Resin 230 epoxy composition

Safety and health certificate for FibARM® Resin 230 epoxy composition

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Thank you for your attention!

CONTACTS : NICKUNJ SHAH - C M DMISHAL SHAH - C O O

Mr. S. C. Mehta –Project Manager-CompositesMob. +91-9324336731NICKUNJ EXIMP ENTP P LTDSir Joravar Bhavan, 93 Maharshi Karve Rd.Marine Lines ,Mumbai 400,020 {INDIA}Tel: +91-22- 43220335/300, 22190300,ext-335 Fax: +91-22-22060415Email: [email protected]

[email protected]

CONTACTS : NICKUNJ SHAH - C M DMISHAL SHAH - C O O

Mr. S. C. Mehta –Project Manager-CompositesMob. +91-9324336731NICKUNJ EXIMP ENTP P LTDSir Joravar Bhavan, 93 Maharshi Karve Rd.Marine Lines ,Mumbai 400,020 {INDIA}Tel: +91-22- 43220335/300, 22190300,ext-335 Fax: +91-22-22060415Email: [email protected]

[email protected]

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mailto:[email protected]




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Carbon Products By Nickunj Eximp ENTP Private Limited, Mumbai