Dramix®

Dramix® economic concrete reinforcement for safe floors on piles

Test, specify and build

33. Floors On Piles Brochure Final.indd 1 21-04-2009 11:39:04

 474

FB1
PK1

375
9
75 75 150

75

150
75
FB1a
500

Table of contents
375
PK1
8
03 Introduction
04 Application field
04 Materials
375
FB1d

09 System performance, calculation of Md

515

10 Calculation of Mu
PK1 12 Punching
7 12 Execution details
13 Quality examinations
375

13 Standard specification text

14 Bibliography
FB1e
511

PK1
375

6
4315

FB2a
440

375

PK1
5
FB2a
440

375

PK1
4
3

375
FB2a
440

75 75 150
75

PK1
150
75

333. Floors On Piles Brochure Final.indd 2 21-04-2009 11:39:39

 474

FB1
160 150

PK3

467

FB1a
500
PK3
INTRODUCTION

508
My aim is to familiarize the reader with the behaviour of
steel fibre reinforced conrete, to draw his attention to the

FB1d
specific characteristics of this product, the importance of the
515

performance described by the EN standard and propose a

relevant technical solution to reach together a better quality
and safety on each job site.
PK3
This brochure is meant primarily for those who are active in
514

the construction market (investors, contractors, designers)

and more specially in the field of industrial floors.

Initially, floors were applied either plainly or reinforced with

Anne Hoekstra conventional reinforcing steel welded meshes.
FB1e

Technical Manager Flooring

It was, however, only in the early seventies that the first
511

experimental work was undertaken with Steel Fibre Reinforced

Concrete (SFRC).

SFRC
PK3is defined as concrete, containing discontinuous steel
fibres, which are homogeneously mixed into the concrete.
475

Since then, SFRC has been used extensively in most of

the world’s industrialized nations, for a wide variety of
applications. Uses of SFRC in industrial floor applications
FB2a

vary from traditional saw cut floors, over jointless floors, and
440

to most structural floor on pile application.

Multiple research studies and tests on the behaviour of steel

PK3reinforced concrete have been carried out in recent
fibre
years in various countries. They have greatly contributed to a
440

better characterization and understanding of the behaviour of

this material. They have also contributed to the specification
of minimum performance requirements for each type of
application.
FB2a
440

During the period 2003 – 2007, a Dutch expert commission

focused on the materials, test methods, design principles and
execution
PK3 controls for pile supported steel fibre floors. This
has resulted in the CUR 111 recommendation document.
440

FB2a
440

PK3
30

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 1. APPLICATION FIELD

This document discusses test methods, design and execution for a pile – suspended concrete industrial floor,
reinforced with Dramix® steel fibres.

This guideline can only be used for:

- Industrial floors and not for other applications, such as pile-suspended rafts for residential or other use.
- Dramix® steel fibre reinforcement, and not for other steel fibres, synthetic fibres or traditional mesh reinforcement.

2. MATERIALS

2.1. Concrete:

Concrete quality in accordance with EN 206, produced and delivered according to local concrete standards:
- Minimum Concrete Quality: C20/25
- Maximum Concrete Quality: C30/37

The grading of aggregates will be in accordance with the applicable standards. The concrete composition must be
engineered in order to obtain homogeneous distribution and good finish ability. For detailed information, consult our
product data sheets and our recommendations on handling, dosing and mixing.

2.2. Steel fibres:

Dramix® steel fibres are designed especially for the reinforcement of concrete. They are made of prime quality
hard-drawn steel wire to ensure high tensile strength at extremely close tolerances.
Provided with hooked ends, they deliver optimum anchorage.

Minimum fibre requirements are:

1 Fibres with CE- marking system 1, According to EN 14889, a minimum

steel fibre for structural use performance level must be reached.
(conform EN 14889-1-2006) As such for every fibre type a minimum
For detailed info, please request our CE info sheet. dosage is required to have CE marking
system 1.

Download info sheet at:

www.bekaert.com/building
CE info sheet

2 Fibres out of drawn wire, with a tensile strength of steel wire > 1000 MPa min.

3 Dimensional tolerances in accordance with EN 14889-1.

4 Best anchorage system : hooked ends for optimum anchorage.

5 Minimum fibre length : 2 times the maximum coarse aggregate size.

6 Maximum fibre length : 2/3 of the hose diameter of the pumping machine.

7 Glued fibres for improved and risk-free pump ability and mixing.

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 Depending on the design results,the recommended fibre types are:

Dramix® RC-65/60-BN:
Dramix® Easy Mix
Dramix® Hi Perform

Dramix® RC-80/60-BN:
Dramix® Hi Perform

Specific product data sheets are available on request

Want to know more about:
- Product characteristics
- Approvals
- Features and benefits
- How to use

Download info sheets at:

www.bekaert.com/building
2.3. Steel fibre reinforced concrete: CE info sheet

The performance of a Dramix® reinforced concrete is mainly determined by following characteristics:

- The performance of the fibre in the matrix (geometry, length/diameter ratio, method of anchorage, tensile strength,…)
- The performance of the concrete matrix
- The amount of fibres in the mix

In order to define the steel fibre concrete specification, a three steps analysis must be made.

1 Minimum dosage for a needed fibre overlap.

2 Minimum total fibre length.

3 Dosage based on performance.

2.3.1. Minimum dosage based on minimum overlap:

Minimum fibre overlap:

For structurally designed applications, the average distance between steel fibres (s) should be lower than 0,4 lf in
order to ensure a minimum overlap between fibres.

s = 3 π x d f x lf
2

4ρf

Where :

- lf is the length of the fibre

- df is the equivalent diameter of the fibre
- ρf is the fibre percentage

s should be lower than 0,4 lf to ensure a minimum overlap

The formula and “s” limits are taken from the thesis of D.C Mc Kee, University of Illinois, Urbana 1969:
“The properties of an expansive mortar reinforced with random wire fibres.”

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 Fig. 1: Minimum dosage based on minimum overlap

S
S S 2

S lf
S

S 2

Aspect ratio (lf/df) 40 45 50 55 60 65

Min. dosage when

61 48 39 32 27 23
s<0,4 lf mm, kg/m3
Minimum dosages of steel fibres based on different aspect ratios and steel fibre spacing

2.3.2. Minimum dosage based on minimum total fibre length:

In addition to the requirement of the minimum fibre overlap, Bekaert recommends a minimum steel fibre length of
6700 meter/m³ concrete. This fibre length ensures the minimum network effect to provide a specific multi-crack
process and so the redistribution of the loads through the crack-bridging steel.

Minimum kg/m3 according Total fibre

Aspect ratio: I/d (length/diameter) I D fibres/kg
to min. overlap length

50 48 kg/m3 50 1 2.800 6.720

65 35 kg/m3 60 0,9 3.200 6.720

Example to reach three criteria: CE-minimum performance level, Mc Kee “2.3.1.” & minimum total fibre length “2.3.2.”

The crack patterns observed on different tests explain the importance of the total fibre network.

6 Low fibre network High fibre network: multiple cracking

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 2.3.3. Dosage based on performance: residual strength

In order to establish the material properties, test EN 14 651 describes a notch three-point bending test which is the
basis for the stress-strain diagram for steel fibre conrete.

Resulting from this test, a load displacement curve shows the different residual forces measured for predefined crack
mouth openings.
A
F
F

30
δ δ1 δII
75

150

150
75

30 A
25 250 250 25 150
500
section AA

F [ kN ]
detail A
25+1

F kN Fl = load at the first crack CMODl

FFl
1
CMOD1 = the crack mouth opening displacement at 0,5 mm FR1 = load at CMOD1.
CMOD2 = the crack mouth opening displacement at 1,5 mm FR2 = load at CMOD2.
FR,1
FR,1 CMOD3 = the crack mouth opening displacement at 2,5 mm FR3 = load at CMOD3.
CMOD4 = the crack mouth opening displacement at 3,5 mm FR4 = load at CMOD4.

FR,2
FR,2

FR,3
FR,3

FR,4
FR,4

CMOD [ mm ]
CMOD mm
0,05
0,05
7 CMOD
CMODL L
CMOD
CMOD = 0.5
= 0,5
1 1
CMOD
CMOD2 2== 1.5
1,5 CMOD
CMOD33==2,5
2.5 CMOD
CMOD = 3.5
4 4 = 3,5

33. Floors On Piles Brochure Final.indd 7 21-04-2009 11:40:13

 Based on this test, the absolute minimum residual flexural tensile strength is:

f(r1) = 4,1 N/mm²

f(r4) = 3,1 N/mm²

minimum residual flexural tensile strength for a C30/37 concrete

These values are proposed for a concrete class C30/37, usually specified for a pile-supported floor.
Compressive strengths with a too low or too high strength class may have undesired side effects.
Please contact your local Bekaert representative in order to get the minimum residual values for other concrete classes.

For the same concrete matrix, the performance level is significantly influenced by the fibre type (e.g. the anchorage
type, the aspect ratio (length to diameter) and the fibre dosage. The higher the aspect ratio and fibre content,
the better the performance of the SFRC.

Why use the EN 14 651 beam test method and not a round indeterminate plate test:

To determine the performance of SFRC for a floor application, the beam test is much more appropriate than a
round indeterminate plate test.

1 Technical Report TR63 “Guidance for the design of Steel-Fibre-Reinforced concrete” outlines that round
indeterminate plate tests are not covered by standards and are not a suitable method to determine the
fundamental properties of SFRC.

2 In a statically indeterminate plate test, the flexural resistance is not related to the crack width.

3 Results of round plate tests are interpreted using yield line analysis in which the flexural resistance is
assumed to be constant along the yield lines. In reality, the pattern of yield lines varies very much,
and so too the crack width along these yield lines. Therefore the flexural resistance derived from statically
indeterminate plate tests depends heavily on assumptions made in the analysis.

4 The structural response should be predicted from rigorous material models rather than the other way around.

The yield lines formed - as well as the total yield line length - in the system test set-up, significantly vary a lot over different test results
and can therefore not be used to derive a uniform flexural resistance value.

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 Why yield-line theory should not be used:

1 No information is given on support reactions or deflections.

2 The adverse effects of pattern loading, such as uplift at piles, are not considered.

3 The design may be unsafe if not all the critical

mechanisms have been investigated.

4 The method is only valid when slabs have adequate ductility for the assumed yield lines to develop. It is not
possible to verify whether this is the case since the analysis provides no information on slab deformations.

5 Calculating the bending moments has to be done with the real pile distances. Decreasing “the design center to
center distance” with the pile and/or floor thickness is not allowed.

2.4. Additional mesh or rebar:

The yield stress of the reinforcement is 500 N/mm2. When different, the design must be adapted in line with local
standards.

3. SYSTEM PERFORMANCE CALCULATION OF Md

3.1. Minimum design information:

- Floor layout
- Pile or pile head dimensions
- Spans between piles in x and y direction
- Floor loads
- The edge of the floor field: line or point supported

3.2. Loads:

Design is made for various load situations

- Floor completely and fully loaded

- Fields loaded - unloaded load case
- Point and wheel loads } maximum bending moments to be calculated on top and bottom

- Restrained shrinkage

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 Restrained shrinkage:

Variant 1 1 : :Nkrimp
Variant = 0,75
Nkrimp ε'f ε'EffE
= 0,75 .hf.hand
andMM krimp==EE
krimp f f. I.floor
Ifloor.Κ
.Κkrimp
krimp

Variant 2 2 : :Nkrimp
Variant = ε'
Nkrimp =fε'
,E .hf.h
f, fE

Unity
Unity check:
check:

Mrep
Mrep +M+ krimp
Mkrimp Nkrimp
Nkrimp
Variant
Variant 1 1 : :—————— ————— ≤ ≤11
——————+ + —————
Mwmax
Mwmax b.h.ft,rep,i
b.h.ft,rep,i

Mrep
Mrep Nkrimp
Nkrimp
Variant
Variant 2 2 : : ––––––––––
––––––––––+ + ––––––––––
–––––––––– ≤1
≤1
Mwmax
Mwmax b.h.ft,rep,i
b.h.ft,rep,i

4. CALCULATION OF Mu

In each cross section Md ≤ Mu

The maximum allowable bending moment in steel fibre concrete Msfrc is calculated by a cross-sectional equilibrium.
The stress-strain relation conforms to EN 14651.

In a floor construction, yield lines must be developed and this aspect of behaviour will not occur in a notched beam,
where we have only one crack. The EN 14651 test does not reflect multiple cracking.
And for this reason, it is allowed to calculate with mean values.

Consequently the CUR 111 clearly expresses:

“The mean (uni-axial) tensile strength is used as the starting value since the redistribution capacity of steel fibre
Calculating of the
reinforced concrete additional
industrial reinforcement:
floors founded on piles, also regarding the minimum fibre content, is such that the use of
the mean value of the uni-axial tensile strength as a basis for design is accepted, rather than the characteristic lower
The maximum allowable bending moment in steel fibre concrete is calculated by a cross-sectional equilibrium.
limit value.”
The stress-strain relation conform EN 14651.

stress In this:
Stress-strain diagram
compression fcd = design value of the compressive strength
fcd
fftd,1 = tensile strength design value of SFRC

fftd,2 = tensile strength design value at

CMOD = 0,5 mm
0.1‰ 0,45 * FR1
fftd,2 =
γm
εt,2 fftd,3 = tensile strength design value at
25‰
CMOD = 3,5 mm
strain
fftd. 3 εc,1 εc,2 0,37 * FR4
tensile fftd,3 =
fftd. 2 1.75‰ 3.5‰ γm
fftd. 1

In this: ffcd = design value of the compressive strength.

fftd,1 = design value of the tensile strength of SFRC.

10

fftd,2 = design value of the tensile strength at CMOD = 0,5mm

0,45 * FR1
fftd,2 = ——————
γm
33. Floors On Piles Brochure Final.indd 10 21-04-2009 11:40:47
 0,45 * FR1
fftd,2 = ——————
γm
fftd,3 = design value of the tensile strength at CMOD = 3,5mm
0,37 * FR4
fftd,3 = —————
γm
In view of the relatively small contribution of fftd,1, to the bending moment resistance, it is justified to use the
relation shown in the next figure.

In view of the relatively small contribution of f ftd,1 to the bending moment resistance, it is justified to use the relation
shown in Simplified
the next figure.
stress-strain
stress

compression
fcd

25‰
strain
fftd. 3 εc,1 εc,2
tensile fftd. 2 1.75‰ 3.5‰

The below diagram illustrates the theory and contains the equations based on cross-sectional equilibrium for a
specifically assumed strain distribution over the height of the cross-section.
The below diagram illustrates the theory and contains the equations based on cross-sectional equilibrium for a
specifically assumed strain distribution over the height of the cross section.
Cross-sectional equilibrium

ffcd εc,2 = 3,5 ‰

7/ 15
N1 - 18.hxu

εc,1 = 1,75‰
hxu

fftd ,2
Mu
+ d
1/3(h-hxu)
T2,2 1/2(h-hxu) h
T2,1

+
εs
T1

As

ε ft εft
fftd,2 = (fftd,2 - fftd,3)
25.10-3
Formulae:

th N1 = 0,75 hxub ffcd

d-hxu
T1 = Asσs = AsEsεs = AsEs (
Formulae:
) 3,5.10-3 < Asfsy
hxu
N1 = 0.75hxuεbffcd
ft
T2,1 = b (h-hxu)(fftd,2 - (f -f ))
25.10-3 ftd,2 ftd,3 d - hxu
T1 = Asσs = AsEsεs = AsEs ( ——— ) 3.5.10-3 < Asfsy
ε
T2,2 = 1 b (h-hxu) ft
(f - f )) hxu
2 25.10-3 ftd,2 ftd,3εft
T2,1 = b(h-hxu)(fftd,2 - ——— (fftd,2 - fftd,3))
Horizontal equilibrium: ∑ H = 0 :25.10
N1 =-3T1 + T1,2 + T 2,2
1 11 ε 1
Bending moment equilibrium:
T2,2 = — Mftu = 18
b(h-hxu) ———— hxu-fftd,3
(fftd,2 N1 +) 2
(h-hxu) T2,1 + 13 (h,hxu) T2,2 + (d-hxu) T1
2 25.10 -3

If Md > Msvb then Mreinforcement ≥ Md- MSFRC

Horizontal equilibrium:
∑ H = 0 : N1 = T1 + T1,2 +T2,2
The amount of reinforcement is calculated in the normal way
Bending moment equilibrium:
11 1 1
11 Mu = —— hxu N1 + —— (h-hxu)T2,1 + — (h-hxu) T2,2 + (d-hxu) T1
18 2 3

If Md>Msvb then

33. Floors On Piles Brochure Final.indd

M 11 21-04-2009 11:40:48
reinforcement > Md-MSFRC
 FUNDERING VLOER OP PALEN,

375
EA. OPLEGPUNTEN PK1
OPMERKING: ANALOOG DETAIL VOOR ANDERE
5

ASLIJN VLOERPAAL
OPLEGPUNTEN (OOK OP STEUNBLOKKEN
OP PAALKOPPEN PK 3 , ENZ.)

FB2a
440

375
75
PK1
5. PUNCHING

150
ASLIJN VLOERPAAL VLOERPAAL 4

3
For the most critical areas for punching - around columns and piles - crack openings have to be limited in order to
BOVENWAPENINGS - NET
have sufficient shear resistance through the concrete section. Therefore, a basic traditional upper reinforcement

375
FB2a
8/8/150/150 MET ONDER

75

440
(mesh or rebar) always needs to be applied.
AANGELASTE
AFSTANDSHOUDERS,
PERFECT OP PAAL
When longitudinal reinforcement bars are provided, CUR 111 allows the contribution of concrete and steel
GECENTREERD
PK1
fibres in the total shear 75stress resistance.
75
3
On the other hand, the CUR recommendation
150 clearly describes that a fibre only floor can not be designed using the
fibres in the punching shear resistance.
PLAN

375
FB2a
440
Fig. 2: Pile head detail
Concrete floor
BOVENWAPENINGS - NET
MET ONDER - POLIERBETON 22 cm ,
AANGELASTE PEBENOR
plastic sheet
zie bestek
PK1
AFSTANDSHOUDERS - DOORZICHTIGE PE-FOLIE 0,2mm
Soil
- GESTABILISEERD ZAND 13cm
Concrete cover
dekking 3 cm 0,00 2

375
FB1f
505

283
PK1 FB1g
1'

25
1

35 85
585

A
Punching check has to be done based on the codes.
There is no agreed method for calculating the designed shear strength of fibre reinforced concrete without
conventional reinforcement.

It is necessary to limit crack widths in the punching area. In case of a too big crack width, the shear resistance
capacity will decrease. It is only possible to realistically calculate crack widths in statically indeterminate structures
without conventional reinforcement by carrying out a non-linear analysis, which is impractical for design.

The maximum crack opening is a direct consequence of the total fibre network. It is prohibited to use fibre
dosages lower than the minimum dosage based on the total fibre length.
See “2.3.2. Minimum dosage based on minimum total fibre length”

6. EXECUTION DETAILS

Depending on the specific project circumstances,

specific execution details (joint profiles, Benefit from our total design
special reinforcement,…) have to be applied. management:
For your tailor-made job site details, - Joint profiles
please contact your local Bekaert specialist. - Reinforcement details
- Concrete compositon
Contact your local bekaert specialist
or: infobuilding@bekaert.com

Execution details

12

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 7. QUALITY EXAMINATIONS

Your Bekaert local specialist can support you with a comprehensive quality control program.

Generals:
- Check the top level of all piles and foundations beams. These must be below the bottom of the concrete floor to allow casting.
- Check the level of the subbase.
must be leveled to +0 ; - 20 mm of the bottom of the concrete floor.
- Check whether the plastic sheet is placed correctly, with enough overlap and fixed in such a way that the sheet will
not curl up during the casting of the steel fibre concrete.

Must be in line with the Bekaert detailed drawings:

- The extra reinforcement is placed. The top and bottom reinforcement need enough support to hold it in place
during the concrete casting process.
- The reinforcement concrete cover.
- The joint profiles are positioned and oriented correctly.

- The concrete mix needs to be designed and adapted in such a way that Dramix® fibres can be mixed easily and
a good concrete workability is obtained. Moreover, the maximum water/cement ratio is 0,5.
Contact your local Bekaert specialist for optimal steel fibre concrete recepies.

Must be in line with the Bekaert design:

- The concrete thickness during casting.
- The right fibre type is used.
- The fibre dosage: check through several washing out tests (when an automatic dosing machine is not applied)

- If needed: start up a quality program with beam tests, produced in accordance with the EN 14 651 in order to
control the performance. Our concrete lab is an open door for jobsite test programs. Contact your Bekaert
specialist.

8. STANDARD SPECIFICATION TEXT

1 Fibres
- Fibres to comply with European Standard EN 14 889-1.
- Fibres with CE-marking system 1. Fibres out of drawn wire, with a tensile strength of
steel wire > 1.000 Mpa min. Dimensional tolerances according to CE.
- Minimum fibre length : 2 times the maximum coarse aggregate size.
- Maximum fibre length : 2/3 of the hose diameter of the pumping machine.

2 Performance
- Minimum total wire length/m³ should be 6.700 meter in order to ensure the
minimum network effect.
- Minimum fibre overlap according to Mc Kee Theory.
- Residual flexural tensile strength in accordance with the design, but as absolute minimum.
f(r1) = 4,1 N/mm²
f(r4) = 3,1 N/mm²
- Concrete quality and additional reinforcement in accordance with design note.

3 Fibre concrete
- Glued fibres for improved and risk – free pumpability and mixing.
- It is prohibited to use loose steel fibres which will cause balls during mixing.

Download at: www.bekaert.com/building

13

33. Floors On Piles Brochure Final.indd 13 21-04-2009 11:41:02

 9. BIBLIOGRAPHY

- EN 206-1:
Concrete – Part 1: Specification, performance, production
and conformity.

- EN 12390-3:
2002 Testing Hardened concrete – Part 3:
Compressive strength of test specimens

- EN 14651:
2005 Test method for metallic fibre concrete

- EN 14889-1:
2006 Fibres in concrete – part 1: Steel fibres
Definitions, specifications and conformity

- NEN 2743:
2003: In situ floorings – execution of monolithic
screeds and paving

- NEN 2747:
2001 Classification and measuring of the flatness and
parallelism of the surface of floorings

- NEN 6700:
2005: Technical principles for building structures
TGB 1990 – general principles

- NEN 6702:
2002: Regulations for concrete
Loadings and deformations

- NEN 6720:
1995: Regulations for concrete – structural requirements
and calculation methods, incl. Amendments documents

- NEN 6722:
2002: Regulations for concrete – Construction

- Technical report n°63:

Guidance for the design of Steel-Fibre-Reinforced concrete

- CUR-Recommendation 111:
Steel-Fibre-Reinforced concrete industrial floors on
pile foundations - design and construction

14

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33. Floors On Piles Brochure Final.indd 15 21-04-2009 11:41:41
 ABOUT BEKAERT

Bekaert is active worldwide in selected applications of its two core competences: advanced metal transformation
and advanced materials and coatings. The combination of these competences makes Bekaert very unique.
Bekaert, headquartered in Belgium, is a technological leader and serves a worldwide customer base in a variety
of industry sectors.

BUILDING WITH BEKAERT

Bekaert products are widely used in the construction sector. Dramix® has given Bekaert a leading position in
the market of steel fibre concrete reinforcement. In 1979, Bekaert introduced Dramix® steel fibres for concrete
reinforcement, designed to offer an easy-to-use alternative for traditional steel mesh and bar reinforcement.
Applications of Dramix® steel fibres include industrial floors, precast elements, tunneling and mining, residential
applications and public works.

Other Bekaert building products

• Murfor® - masonry reinforcement
• Stucanet® - plastering mesh
• Widra® - corner beads
• Mesh Track - road reinforcement

NV Bekaert SA
Bekaertstraat 2
BE-8550 Zwevegem
Belgium
design by BOA-inc.be - 52.25.05

www.bekaert.com/building
infobuilding@bekaert.com

Modifications reserved. All details describe our products and solutions in Customer service:
general form only. For ordering and design only use official specifications T +32 56 76 61 10
and documents. F +32 56 76 79 47
© 2009 Bekaert

16

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