ADVANCED COMPOSITE MATERIALS : AN ALTERNATIVE TO

REINFORCEMENT, TENDONS AND CABLES.

Pradip S Lande
Snr. Lecturer in Civil Engineering Department,
College of Engineering and Technology,
AKOLA – 444 001
ABSTRACT
Steel in the form of bars, cables, tendons etc. as a reinforcing material in cement concrete is
extremely popular and widely accepted construction material all over the world. One of the
major drawback with it , is it’s vulnerability to the environmental attacks and subsequent
electro chemical destruction leading to corrosion which in turn reduces strength and
serviceability of concrete structures. Engineers and scientists are in constant search of an
alternative material which will be corrosion resistant, withstand extreme environmental
conditions, light weight, stronger and fatigue resistant, easy to handle as compared to steel.
Recent developments in the field of ADVANCED COMPOSITE MATERIALS (ACMs)
makes it possible to use them as an effective and efficient alternative reinforcing material in
place of steel and cables. These ACMs are unaffected by electro-chemical destructions and
resists any environmental attacks and has high strength, high impact resistance, less weight,
good thermal insulation property which renders them superior alternative reinforcing material.
This paper presents a comprehensive review of recent advances in composite materials, their
characteristics properties and their applications in place of steel.

1.INTRODUCTION
Steel is one of the most popular and widely accepted construction
material in R.C.C. construction. With the help of this material only, it has become
possible to span large distances, construct huge hydraulic & nuclear structures, building
frames etc. Till today it is the prime material through which designer put forward his
ideas in to practices. Not withstands its admirable qualities such as easy availability, low
cost, high strength, formability, ease in handling, transporting and errection etc, it has one
significant drawback i.e., it’s susceptibility to environmental attack reverting the steel to
it’s natural oxide state i.e. corrosion of steel. Corrosion is a complex electro-chemical
process which expands the steel several times of its original volume and thus leads to
reduction in strength of steel, bond failure, slippage of steel, spalling of the concrete and
deterioration of concrete structures. The most common reason for early degradation,
deterioration and disintegration of a concrete structural member is the corrosion of
reinforcing steel. Due to corrosion of steel large numbers of bridges and other R.C.C.
concrete structures are becoming structurally defective or functionally obsolete requiring
costly maintenance, repairs rehabilitation and retrofitting of structures. It is estimated
than in India yearly the loss caused by the corrosion related damages amounted to several
crores of rupees, about five to six percent of GNP. Though the Engineers try to tackle
this problem by using noncorrosive reinforcement mostly by epoxy coated steel bars but
the permanent solution still evades them.
 Because of these problems with steel, engineers have often wished for an
ideal material which will be stronger, corrosion resistant, withstand extreme
environmental conditions, light weight, high fatigue strength, easy to handle than the
conventional steel. Also the modern science and technology are advancing so fast and
becoming so sophisticated that the materials have to be correspondingly efficient,
effective, high performancable, reliable, with exceptional environmental requirements for
specific use. The conventional material i.e. steel will not be capable of meeting these
demands. The recent developments in the field of Advanced composite materials
(ACMs) has enabled in development of very efficient and effective alternative to steel
bars and cables. These ACMs are unaffected by electro chemical deterioration and resists
corrosive actions due to environmental attacks. Moreover ACMs can be used in many
forms (like bars, plates, cables, wraps etc ). ACMs plates can be used in concrete
members at a face to increase the tension capacity of members ( i.e. for retrofitting ),
whereas ACMs bars as a reinforcement in beams and slabs replacing the conventional
steel bars. It can also be used as cables, tendons in bridges. ACMs Wraps can be used as
retrofitting material around concrete members to improve their strength. This papers
presents a comprehensive review of recent advances in ACMs, their characteristic
properties and their application replacing the steel in Civil engineering structures.

2. ADVANCED COMPOSITE MATERIALS (ACMs)

ACMs can be defined as combination of materials appropriately arranged

using reinforcing fibers, carefully chosen matrixes, and some times auxiliary materials
like adhesive core and other inserts. These combinations after proper manipulation and
processing result in finished structure/item with synergistic properties i.e. properties
achieved after fabrication cannot be obtained by individual components acting alone.
The ACMs can be classified in different categories on the basis of micro structures,
multiphases, reinforcements, manner of packing fibers layered compositions, method of
composition, matrix system processing methods etc. Basic components of ACMs are (i)
Reinforcement (fibers) (ii) Matrix (iii) Honey comb core/adhesives ( for sand witched
structures ). The great variety of fibers materials in various forms, shapes and sizes have
been recently developed for use in ACMs and in the construction industries. Steel, glass,
carbon, Aramid (kevlar), boron, silicon carbide, silicon nitrates, alumina fibers are some
of the commonly used high performance reinforcement fibers in ACMs. The
reinforcements may be called by different names according to sizes such as Whisker
( < 0.025 mm ), fiber ( 0.025 – 0.8 mm ), Wire ( 0.8 – 6.4 mm ), rod ( 6.4 – 50 mm ) and
bar ( > 50 mm ). In general the continuous filamentary type reinforcement is important
from structural application point of view. It is the reinforcement which is primarily
responsible for the mechanical properties of ACMs. Usually all the reinforcements
(fibers) are stronger in tension than steel, but weak in shear ( i.e. brittle ) requiring the
filler material (Matrix) relatively strong in shear which will protect reinforcement against
abrasion or environmental corrosion. Matrix also helps in distributing the load from
reinforcement, absorbing energy, reducing stress concentration and preventing cracks
propagation. Thermosetting and thermo plastic types of organic polymers are used as
Matrix ( e.g. epoxide, phenolic, polyamide resins etc.).
 Some of the important fibers used as reinforcement in ACMs along with
their characteristic properties are discussed briefly.

i) Carbon/Graphite Fibers

Carbon fibers are produced from petroleum pitches in large volumes.

These are low cost, low modulus. The current technology for producing carbon fibers
generally centers on the thermal decomposition of various organic precursors, Rayons
polyacrylonitrile (PAN), pitch, polyesters, polyamide polyvinyl alcohol, polyvinyl
chloride, poly-p-phenylene and phenolic resins have all been considered and investigated
as potential precursor materials for producing carbon fibres. These are produced by heat
treating the precursor to temperature upto 10000c in inert atmosphere. Carbon fibers are
very small in diameter and also manufactured as continuous mats, brails, continuous
straight fibers. These are high strength, high modulus, low density, light weight, and has
significant cost and handling advantage, outstanding creep and fatigue resistance.
Pultruted carbon reinforced composites are noted for their lubricity, wear resistance,
capacity of heat dissipation, and resistance to alkaline and soil solutions. Carbon fibers in
general are not affected by moisture, atmosphere, solvents, bases etc. The Table No 1
Shows carbon fiber properties.

* Table No 1 Carbon Fiber properties

High High modulus Very High modulus
strength
XAS, 3k T300,3k M40 P555 M50 Gy 70 P 75
1 Density (g/cm3) 1.80 1.74 1.81 2.02 1.91 1.96 2.0
2 Tensile strength 3270 3040 2452 2100 2450 1860 2070
(MPa)
3 Tensile modulus 235 226 392 380 490 517 517
(GPa)
4 Elongation at break 1.44 1.30 0.6 0.50 0.5 0.38 0.4
(%)
5 Filament diameter 9 7 6 10 - 8 -
(mm)
6 Precursor PAN PAN PAN PITCH PAN PAN PITCH
(The grades mentioned above are proprietary designation of manufacturing companies)

ii) Glass fibers

On a specific strength (i.e. strength to weight) basis, glass fiber is one of
the strongest and most commonly used structural materials. Some Lab tested fibers has
shown strength upto 6896 MPa and commercial grades range from 3448 – 4830 MPa.
The continuous glass filament are manufacture by two basic process i.e. by marble melt
process and direct melt process respectively. To minimise abrasion related degradation of
glass fibers, surface treatments (sizings) are applied prior to gathering of fibers in to
strands. Commonly glass fibers are round and straight and have diameters ranging from
G (9-10.2 µm) to T (22.9 – 24.1 µm ) are used. The glass fibers are available in different
forms like continuous form, woven roving, surfacing mats, three dimensional and
multidimensional (such as 5-D, 7-D, 11-D ) etc. There are several glass fiber types with
different chemical compositions providing the specific physical/chemical properties.
 E-glass ( calcium aluminoborosilicate composition) is best for general
purpose structural use. S-glass (magnesium aluminosilicate composition) is a special
glass with higher tensile strength and modulus, good heat resistance, strong resistance to
acids. These properties make S-glass fibers suitable choice in ACMs to be used in
elevated temperature and humid environments. C-glass has good chemical stability in
chemical corrosive environments. T-glass fiber exhibits improved performance over E-
glass such as 36% increase in tensile strength, 16% increase in tensile modulus, increased
heat resistance, improved impact, electrical, thermal and chemical resistance properties.
R-glass (magnesium-lime-aluminosilicate ) has higher tensile strength and modulus
compared to E-glass and gives higher resistance to fatigue, aging temperature and
corrosion. A-glass, ECR-glass, AR-glass, D-glass are some types of glass fibers.

Table No. 2 : Glass fiber properties.

E-glass R-glass D-glass S-glass
Density (g/cm3) 2.60 2.55 2.16 2.49
Tensile strength (Mpa) 3400 4400 2500 4580
Tensile modulus (Gpa) 73 86 55 86.93
Elongation at break (%) 4.5 5.2 4.5 5.4
Filament diameter 3-14 3-14 3-14 --

iii) Aramid Fibers

Aramid fibers ( aromatic polyamide ) was introduced by Dupont under
the name Kevlar. The aromatic polyamide are believed to be made by solution
polycondensation of diamines and diacid halides at low temperature. The structure of
aramid fiber is anisotropic gives higher strength and modulus in the fiber longitudinal
direction. Aramid is resistant to fatigue, exhibits good toughness and general tolerance
characteristics. Applications of aramid fiber in civil structures include ropes, cables,
prestressing tendons, pipes, walls etc. Table No 3 shows properties of Aramid fibers.

Table 3. Properties of Aramid fibers

Polyester MONEX Kevlar29 Kevlar49 Teflon
Density 9/cm3 1.38 1.38 1.44 1.45 2.15
Tensile 900 670 2700 3500
Strength(MPa)
Tensile 18 60 135 133 --
Modulus(GPa)
Elongation at 10-15 20-30 4 2.5 20-30
break %
Filament 10-12 -- -- -- 20
diameter

iv) Linear organic Fibers

This fiber may become one of the major reinforcement for civil and
building structure in future. This high strength and high modulus organic fiber can be
produced by arranging the molecular structure of simple polymero to become straight
during manufacture. The properties of this fiber includes rigidity (240 GPa), lower
density (0.97), tensile modulus (117 GPa) and tensile strength (2.9-3.3 GPa)
v) Other notable high performance fibers are boron and silicon carbide fibers (Sic).
Ceramic fibers (including oxide and non oxide) are also developed. Other organic fibers
available are acrylic, nylon, polybenzimidazole (PBI), polyester, polypropylene and
teflon.

3. ACMs AS REINFORCEMENT, CABLES AND TENDONS

3.1. ACMs VERSES STEEL

Technical properties of ACMs depends upon type of reinforcing fibers,
their form, style, proportion, direction etc. The characteristic properties of ACMs bars
when compared with that of a high strength steel (ref fig I) can be summarised as:

i) All the ACMs are stronger than steel.

ii) ACMs with carbon fibers has same stiffness as steel.
iii) ACMs with carbon fibers are stiffer than ACMs with aramid fibers which
inturns are stronger than steel.
iv) Stress strain carves of all ACMs are linear up to failure.
v) All ACMs have less ductility and unpredictable plastic behaviour.
vi) Due to their higher strengths and lower stiffnesses ACMs component develop
much larger strains within elastic limits as compared to steel.
vii) The ACMs has low bond strength which can be overcomed by providing
mechanical anchorages and surface treatment to ACM bars.
The ACMs properties like corrosion resistant, light weight, high tensile strength,
high fatigue strength, withstanding extreme environmental attacks, zero electrical
conductivity, high impact resistance, smooth and fine finishing with various colours, easy
fabrication, handling, errection, vibration damping characteristics makes it far superior,
efficient and effective and reliable construction material in place of steel.
3.2 ACMs as cables and Tendons.

The application of ACMs in bridges as cables and tendons have been

reported from different countries. As ACMs cables are much lighter, stronger than the
conventional steel cables much longer distances can be spanned by ACMs cable. In
costal areas where corrosion of steel cables is a very big problem, ACMs cables proves
efficient and effective alternative. The state of the art application is cable stayed bridges.
The pultruded cables and tendons of ACMs supporting concrete decks and girders in
bridges render the structures stronger and durable than steel.
The following are some of the case studies reported on use of ACMs as
cables and tendons.
• Pultruded cables using several hundred parallel carbon fibers composite wires (6 mm
dia. pultruded from 500000 carbon fibers) using epoxy resin system. Bundled wires
are embedded in a polymer matrix, non carbon radicals are then burned off in an inert
atmosphere and replaced by carbon. These pultruded cables can yield two to three
times the specific strength of steel and could last more than 100 years, permit longer
span cable stayed bridges ( upto 6 to 9 km ). The steel cables would snap under their
own weight over such a distance.
• The idea of joining Europe and Africa across the strait of Gibraltar is being under
serious consideration by using carbon fiber composite cable stayed bridge ( ref fig.2 ).
• The Ullenbergstrace bridge in DUSSEL-DORF and Marienfelde bridge both in
Germany are the first kind of post tensioned bridges incorporating tendons using glass
fiber ACMs. Both the bridges are two spans each ranging between 20 to 25 m.
Difficulties were observed in attaching the anchorages to the tendons. Slipping out
and breaking out of tendons prematurely was reported. As the modulus of elasticity
of glass fiber ACM, tendon is low leading to a strain as high as 2% at working stress
level during initial prestressing which produce very long elongation of prestressing
tendons and should be accommodated by long anchorages and enough space behind
anchorages.(refer fig 3, 4 )
• Pretensioned slab on girder bridges and posttensioned using aramid fiber ACM
tendons and carbon fiber ACM tendons have been reported from Japan.
• The Heavy Assault bridge made for the U.S. Army is to be carried in three jointed
sections on a armored vehicle, unfolds hydraulically to create 106ft. span and
supports 70 ton load. Twelve carbon-epoxy chords about 38 ft long and 4x5 inch in
cross section supports the structure.
• ARAPREE is a composite prestressing tendon consisting of aramid filaments and
epoxy matrix. The mechanical properties of rectangular strip (20 mm x 1.5 mm) with
50% fiber volume are : tensile strength 2800 MPa, Young’s modulus 125-130 GPa,
failure strain 2.4%, density 2.4, Relaxation is 15 to 20%.
• AFRP ROD from Teijin is another concrete reinforcing tendon using Technora aramid
fibers. Mechanical properties of a typical 6 mm diameter rod with 65% fiber volume
are : tensile strength 1862 MPa, tensile modulus 52.9 GPa, failure strain 3.7%,
relaxation 7-14%.
• CFCC is the carbon fiber composite cable from Tokyo Rope Manufacturing
Company. PAN based carbon fiber is impregnated with epoxy. The Mechanical
 properties of typical cable (Seven strands, dia. 0.49 inch ) are : tensile strength 2118
MPa, tensile modulus 137 GPa , specific weight 1.5, elongation at break 1.57 %,
relaxation loss upto 2.46%, creep 0.04%, bond stress 7.2 MPa.

3.3 ACMs as Reinforcement

It has been reported that ACM reinforced bar behave in the same manner as that
of steel bars in the slabs and beams1. Due to their less young’s modulus deflection was
considered as a limiting criteria in case of ACM reinforced beams. In slabs ACM bars
are used as reinforcement in the form of composite grids, when compared with steel grid,
the maximum load supported by slab reinforced with ACM grid was observed to equal or
more than slab reinforced with steel grid2. Slabs when reinforced with 3-D continuous
carbon fiber and loaded exhibited non linear behavior and reduction in stiffness in post
cracking stage3.
Kajima-FRC reported a type of composite concrete called 3R-FRC in
which 3-D fabric, made by weaving the fiber rovings in three direction is impregnated by
epoxy and cured, and is employed as main reinforcement. The fiber is a hybrid of PAN
based carbon, aramid and vinylon fibers. NEFMAC is also a kind of composite
reinforcement for concrete. A hybrid of continuous carbon, glass and aramid fibers is
impregnated with resin and formed into mesh enabling thinner section of concrete to be
used.

4 COST ECONOMICS
In general composite products for main reinforcement of concrete, cables
and tendons are more expensive than steel on the basis of weight for weight thereby
prohibiting use of ACMs extensively in structural applications. However weight is not
logical basis for cost comparisons. A more rational basis should be strength. The
corrosion resistance, nonmagnetic properties, low electrical conductivity, weather
durability, light weight and other properties of ACM’s may play an important role for
engineers to select ACM reinforcement instead of conventional steel. If the cost of
corrosion rehabilitation and repairs of R.C.C. structures is to be considered, ACMs cost
could be comparable with steel. With the increase amount of usage, adopting a good
design scheme, increase opportunities for application, sophistication in technology the
cost of ACMs will be decreased considerably in future.

5.CONCLUSION
Considering ACMs properties it can be said that ACMs are very effective
and efficient and attractive alternative to reinforcing steel bars, cables and tendons.
ACMs are being considered in several developed countries as a potential construction
material in place of steel. Some of ACMs have been successfully applied to bridges and
other structures. It can be hoped that day is not very far when ACMs will become good
substitute for steel, tendons and cables in respect of both performances and price.
6.REFERENCES:

1) Brown V.L and C.L. Batholomew (1993). Fibre reinforced bar in reinforced concrete members. ACI
materials Journal 90( 1); 34-39
2) Banthia N.M. AL. Aslay and S.Ma (1995), Behavior of concrete slabs reinforced with fibers plastic grid
ASCE Journal of materials in CIVIL Engg.
3) Ahmad S.H.P. zia, T.J. Yu and Y Xie (1994) punching shear test of slab reinforced with 3D carbon Fiber
fabric . ACI concrete International design and construction .
4) KIM P and U.Meier (1991) CFRP cables for large structures , Advanced composite materials in civil
engineering structures proceedings Las Vagus.
5) Abhijit Mukherjee (1997) Application of Fiber reinforced polymer composite in repair and strengthening
of structures. International conference on maintenance and durability of concrete structures Hyderabad
proceedings.
6) V.Ramakrishanan (1993) Recent Advancements in concrete Fiber composites. International symposium
of innovative world of concrete (ICI-IWI-93) .
7) Baidar Bhakht, Leslie Jaeger, Aftab Mufti, Plastic bridges. Architectural journal .
8. D.H.Kim, composite structures for civil and Architectural Engineering.
9. Dr.P. Mitra, Advanced composites, plastic vision India 1992.
10. J.E. Sumevak, Pultrusion an Expanding Technology.
 Date :
To,
Mr. P.C. Sharma
Editor
New Building Materials and
Construction World,
165, Jullena, Adj. Escort Heart Institute
NEW DELHI – 110 025

Reference : (i) Your letter NBM/PERLET/0601 dated 14 sept.2001.

(ii) My Fax No – dated 01-10-01.
Subject : Forwarding the technical article
(i)‘Advanced composite materials : An Alternative to
Reinforcement, Tendons and cables’
(ii) ‘Reinforced Earthwork Approach Embankment Using ‘KOLOGRID’
for R.O.B. At Murtizapur (M.S.) : A Case Study’.
Dear Sir,
With reference to above I am sending re-polished article “Advanced
composite materials : An alternative to Reinforcement, Tendons and cables”, and a new
technical article titled “ Reinforced earthwork approach embankment using kologrid for
R.O.B. at Murtizapur (M.S.) : A Case Study”. I am very much thankful to you for giving
me opportunity to publish my articles in your prestigious and esteem journal. Hoping
you will also find 2nd article useful for publishing. This article has been selected for
National Seminar to be held at Bhubneshwar in month of Nov.2001.
May I request you to send me copies of the journals in which articles will
be published. I also request you to enroll me for subscription by adjusting amount of
honorarium for three years.
Kindly acknowledge the same.
Thanking you.

Address for correspondence is given below.

Address : Yours sincerely,
Pradip S. Lande
Shree Apartment Pradip S. Lande
Chaitanyawadi, Near Sr.Lecturer in Civil Engineering
S.B.I. Colony No 5, Small College of Engineering & Technology,
Umari, AKOLA (M.S.) 444 005 AKOLA
Fax : (0724-59024)