In the research project WiFaPu (Wrapping process for highly fiber-reinforced concrete using the example of a pump sump), a new production process for components made of short fiber-reinforced textile concrete with textile reinforcement was developed. This process enables the production of components with any cross-sectional thicknesses by wrapping thin, short fiber-reinforced concrete layers around an inner formwork. A key challenge was to develop a concrete mixture that is both pumpable and adheres to the formwork during wrapping, while avoiding cold joints and minimizing shrinkage and cracking. The mixture needed to balance high durability, strength and a strong bond with AR-glass fibers, while reducing CO2 emissions and resource consumption. To meet these demands, a tailored mixture is developed. AR-glass short fibers are added to minimize shrinkage deformations. The cement content is reduced by substituting part of it with metakaolin (calcined clay), lowering the CO2 footprint. The aggregate content is increased to further decrease cement use. The fresh concrete properties are optimized by adjusting the type and amount of superplasticizer. Industrially manufactured expanded glass is used instead of natural aggregate to conserve natural resources and reduce component weight. The addition of short fibers significantly enhances the tensile strength of the textile concrete composite. Especially in mixtures containing metakaolin and short fibers, durability is improved due to high resistance to external influences, as evidenced by freeze-thaw testing. In summary, the investigations demonstrate that targeted adjustments to the concrete composition can optimize the performance and sustainability of short-fiber-reinforced textile concrete for the wrapping process.

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Short-Fiber-Reinforced Concrete Meeting the Demands of Wrapping Textile-Reinforced Concrete

  • Fabian Kufner,
  • Petra Rucker-Gramm,
  • Michael Horstmann

摘要

In the research project WiFaPu (Wrapping process for highly fiber-reinforced concrete using the example of a pump sump), a new production process for components made of short fiber-reinforced textile concrete with textile reinforcement was developed. This process enables the production of components with any cross-sectional thicknesses by wrapping thin, short fiber-reinforced concrete layers around an inner formwork. A key challenge was to develop a concrete mixture that is both pumpable and adheres to the formwork during wrapping, while avoiding cold joints and minimizing shrinkage and cracking. The mixture needed to balance high durability, strength and a strong bond with AR-glass fibers, while reducing CO2 emissions and resource consumption. To meet these demands, a tailored mixture is developed. AR-glass short fibers are added to minimize shrinkage deformations. The cement content is reduced by substituting part of it with metakaolin (calcined clay), lowering the CO2 footprint. The aggregate content is increased to further decrease cement use. The fresh concrete properties are optimized by adjusting the type and amount of superplasticizer. Industrially manufactured expanded glass is used instead of natural aggregate to conserve natural resources and reduce component weight. The addition of short fibers significantly enhances the tensile strength of the textile concrete composite. Especially in mixtures containing metakaolin and short fibers, durability is improved due to high resistance to external influences, as evidenced by freeze-thaw testing. In summary, the investigations demonstrate that targeted adjustments to the concrete composition can optimize the performance and sustainability of short-fiber-reinforced textile concrete for the wrapping process.