Fibre reinforced concrete (FRC) is defined as a composite material consisting of concrete

reinforced with discrete randomly but uniformly dispersed short length fibres. The fibres can be
made of steel, polymer or natural materials. Woven fabrics, long wires, bars, and continuous
wire mesh are not considered discrete fibres.

FRC is considered as a material of improved properties and not as reinforced cement concrete
whereas reinforcement is provided for local strengthening of concrete in tension region. Since in
FRC, fibres are distributed uniformly in concrete, it has better properties to resist internal stresses
due to shrinkage. As fibres improve specific material properties of the concrete, impact
resistance, flexural strength, toughness, fatigue resistance, ductility also improve.

Fibres generally used in cement concrete pavements are steel fibres and organic polymer fibres
such as polypropylene and polyester.

Steel Fibre Reinforced Concrete

Steel fibres have been used for a long time in construction of roads and also in floorings,
particularly where heavy wear and tear is expected. Specifications and nomenclature are
important for a material to be used as the tenders are invited based on specifications and
nomenclature of the items. Such nomenclature is not available in Delhi Schedule of Rates. In a
work where steel fibre reinforced concrete was used for overlays just like flooring, the following
nomenclature can be adopted for concreting of small thickness.

Providing and laying 40 mm steel fibre reinforced cement concrete in pavement (in panels
having area not more than 1.5 sqm) consisting of steel fibre @ 40kg per cubic meter of concrete
and cement concrete mix of 1:1.95:1.95 (1 cement: 1.95 coarse sand of fineness modulus 2.42:
1.95 stone aggregate 10 mm and down gauge of fineness modulus 5.99) over existing surface i/c
cement slurry, consolidating, tapping, and finishing but excluding the cost of steel fibres which
shall be paid separately, complete as per direction of Engineer in Charge (Cement to be used
shall be OPC 43 grade and sand and aggregate have to be washed).

Second item of fibres was provided separately as “Providing and mixing steel fibres of dia 0.45
mm in cement concrete duly cut into pieces not more than 25 mm in length.”
Figure-1: Pavement with steel fibre reinforced concrete

Though the item of steel fibre reinforced concrete has been provided with a design mix of
concrete, which is almost of 1:2:2 grading, it can now be used of mix like M30 or M35. Since in
the executed item, the thickness was to be restricted, the stone aggregates used were of 10 mm
size and below however, in case of the concrete of more than 75 mm thickness, stone aggregates
of 20 mm grading can be used.

The construction was carried out more than a decade back. It is observed that the performance of
the concrete is satisfactory even after many years of construction (Figure 1). Even, no corrosion
has been observed in the steel fibres. In fact the concreting has been done just like flooring item
in this case over already existing hard surface. In such a case a bonding coat should also be
provided like a coat of cement slurry. The fibre reinforced concrete has been provided in small
panels considering the workability. Though vacuum dewatered concrete has not been done with
steel fibre reinforced concrete but the same is also possible. Vacuum dewatered concrete, though
cannot be done in small thickness like 40 or 50 mm but can be used if thickness is 100 mm or
more.

Figure-2: A view of PFRC used in parking over lean base concrete

Figure-3: Laying of PFRC in parking over WBM surface

Polymer Fibre Reinforced Concrete

Polymeric fibres are being used now because of their no risk of corrosion and also being cost
effective (Sikdar et al, 2005). Polymeric fibres normally used are either of polyester or
polypropylene. Polymer fibre reinforced concrete (PFRC) was used on two sites with ready mix
concrete and Vacuum dewatering process.
The nomenclature can be used in the works as given here.

"Providing and laying ready mix fibre reinforced cement concrete of M35 grade (The concrete
shall also have minimum works test beam flexural strength of 40 kg per sqm at 28 days) in
required slope and camber in panels i/c shaping at drainage points as required using cementitious
materials not less than 435 kg per cum of finished concrete from ACC/L&T/AHLCON/
UNITECH or equivalent batching plant for all leads and lifts with Fibrecom-
CF/Fibremesh/Recron or equivalent (100 % virgin synthetic fibre size 12 mm long) to be mixed
@ 900 grams per cum of concrete i/c finishing with screed vibration, vacuum dewatering
process, floating, trowelling, brooming and normal curing etc. complete as per standard
manufacturer’s specifications and as per direction of Engineer’s in charge (All related equipment
shall be arranged by the contractor. Cost of centering, shuttering, grooving etc. shall be paid
separately. Design Mix shall be got approved from the Engineer in Charge).

In both the sites, vacuum dewatered concrete was used. Both the sites are to be used for parking.
In a site, fibre reinforced concrete was used over a base cement concrete of lean mix of 1:4:8
(Figure 2) while in other site it was laid over water bound macadam (WBM) (Figure 3).

When dewatered concrete it has no problem of water being coming out on surface during
compaction process but when it is done over WBM, a lot of concrete water is soaked by WBM
and thus the concrete loses the water to WBM and the water which comes out during
dewatering/compaction process is not in same quantity asin case of lean concrete. It appears that
it is better to provide base concrete than WBM as the base. The groove was made in one case
before setting of concrete and also panels were cast with expansion joints in one direction. No
cracks were observed in the direction in which expansion joints were provided assuming this is
longitudinal direction. In lateral direction, no joints were provided and the width of such panel
was about 12 m. It was later observed that cracks have developed in this direction (Figure 4).

Figure-4: A closer view of crack due to no expansion joint provided in PFRC on lean concrete
base.
Figure-5: A closer view of crack due to no expansion joint

As it is known that the width of 12 m is too long for expansion/ contraction. It has been observed
that almost at about one–third of the panel width, such cracks developed i.e. size of panel from
one side is about 4 m and from other side it is about 8m. From the site observation, it is therefore
inferred that the panel should have the size of about 4m x 4m in the temperature conditions of
Delhi however small variation can also be made as per site conditions. In other case, the
contractor delayed the cutting of grooves and thereafter the area was occupied due to some
urgent requirements, the cracks in both the directions developed. The cracks were almost in line.
Later on the grooves were made through cutters. It has been observed that the distance of cracks
in one side was almost near to 4 m and on other side at about 7 to 9 m (Figure 5). Thus from this
case study also, inference can be made that grooves if made in panels of 4m x 4m, it would be
appropriate.

In both the cases, no lateral grooves were made, as working was not a problem due to use of
vacuum dewatering process. In both the cases, horizontal line cracks have been observed
indicating that the grooves in other direction are also essential. From this, it is imperative that
polymer fibre reinforced concrete should be laid in panels or grooves should be provided so that
concrete acts like in panels. Cutting grooves is easy as it can be made after casting of the
concrete. But it should not be delayed for long and should be made before concrete achieves its
desired strength. The size of panels may be kept around 4m x 4m.

Thus, fibre reinforced concrete has advantage over normal concrete particularly in case of
cement concrete pavements. Polymeric fibres such as polyester or polypropylene are being used
due to their cost effective as well as corrosion resistance though steel fibres also work quite
satisfactorily for a long time. It appears that fibre reinforced concrete should be laid on base
concrete of lean mix such as 1:4:8 cement concrete rather than over WBM and provided with
grooves in panels of about 4m x 4m to avoid expansion/ contraction cracks. Grooves can be
made after casting of concrete through cutters.

GLASS FIBRE REINFORCED CONCRETE

Glass fibres are used to reinforce cement and concrete. Glass fibre reinforced concrete (GFRC)
comprises hydration products of cement, or cement plus sand, and the glass fibres. Glass fibres
were first used to reinforce cement and concrete in Russia. However they were corroded by the
highly alkaline Portland cement matrix. Therefore, alkali resistant glass fibres have been
subsequently developed in UK and other countries. These are available in the form of continuous
rovings, chopped stand mats, cranette, wool, ropes and woven fabric. Glass fibres coated with
epoxy resin compounds have also been tried out to protect them from alkali attack by Portland
cement.

Glass fibres of 10mm to 50mm in length and a few microns in diameter can be added upto 5% by
weight and premixed with cement and water in a pan or a paddle mixer. Small quantities of
lubricating admixtures, such as polyethylene oxide or methyl cellulose may be added into the
mix. The resulting mix may be sprayed or cast into the moulds. The products can also be
produced either by extrusion or by injection-moulded process. In some of the processes, rovings
can be chopped in-situ and sprayed simultaneously with a slurry of suitable consistency on a
mould of production. This is very effective and convenient for casting shell roofs and sheets.
Addition of glass fibres of about 10% by volume increased the tensile strength by roughly two
times, and the impact resistance by about 10 times. The cyclic loading tests conducted on glass
fibre cement laminates showed fatigue resistance of GFRC roughly comparable with that of
SFRC.

Uses of glass fibres in concrete is very limited because they suffer severe damage and loss of
strength due to abrasion and impact forces generated during movement of aggregates in mixer.
Considerable attention has been paid for thorough understanding of the mechanical properties
and performance characteristics of GFRC in the design of GFRC components. Several projects
were reported for building wall panels made of GFRC in UK and USA. GFRC has also been
used for repair works and for industrial floors in USA.

STEEL FIBRE REINFORCED CONCRETE (SFRC)

Steel fibre reinforced concrete is a composite material having fibres as the additional ingredients,
dispersed uniformly at random in small percentages, i.e. between 0.3% and 2.5% by volume in
plain concrete. SFRC products are manufactured by adding steel fibres to the ingredients of
concrete in the mixer and by transferring the green concrete into moulds. The product is then
compacted and cured by the conventional methods. Segregation or balling is one of the problems
encountered during mixing and compacting SFRC. This should be avoided for uniform
distribution of fibres. The energy required for mixing, conveying, placing and finishing of SFRC
is slightly higher. Use of pan mixer and fibre dispenser to assist in better mixing and to reduce
the formation of fibre balls is essential. Additional fines and limiting maximum size of
aggregates to 20mm occasionally, cement contents of 350 kg to 550 kg per cubic meter are
normally needed.

Steel fibres are added to concrete to improve the structural properties, particularly tensile and
flexural strength. The extent of improvement in the mechanical properties achieved with SFRC
over those of plain concrete depends on several factors, such as shape, size, volume, percentage
and distribution of fibres.

Plain, straight and round fibres were found to develop very weak bond and hence low flexural
strength. For a given shape of fibres, flexural strength of SFRC was found to increase with aspect
ratio (ratio of length to equivalent diameter).

Even though higher ratios of fibres gave increased flexural strength, workability of green SFRC
was found to be adversely effected with increasing aspect ratios. Hence aspect ratio is generally
limited to an optimum value to achieve good workability and strength. Grey suggested that
aspect ratio of less than 60 are best from the point of handling and mixing of fibres, but an aspect
ratio of about 100 is desirable from strength point of view. Schwarx however suggested aspect
ratio between 50 and 70 is more practicable value for ready mix concrete.

In most of the field applications tried out to date, the sixe of the fibres varies between 0.25 mm
and 1.00mm in diameter and from 12 mm to 60mm in length, and the fibre content ranged from
0.3 to 2.5 percent by volume. Higher contests of fibre upto 10% have also been experimented.
Addition of steel fibres upto 5% by volume increased the flexural strength to about 2.5 times that
of plain concrete.

As explained above, mixing steel fibres considerably improves the structural properties of
concrete, particularly tensile and flexural strength. Ductility and post cracking strength,
resistance to fatigue, spalling and wear and tear of SFRC are higher than in the case of
conventional reinforced concrete. SFRC is therefore found to be a versatile material for the
manufacture of wide varieties of precast products such as manhole covers, slab elements for
bridge decks, highways, runways, and tunnel linings, machine foundation blocks, door and
window frames, piles, coal storage bunkers, grain storage bins, stair cases and break waters.
Technology for this manufacture of SFRC light, medium and heavy duty manholes covers has
been developed in India by Structural Engineering Research Centre, Chennai.

Field experiments with two percent of fibre content indicated that SFRC runway slabs could be
about one half the thickness of plain concrete slabs for the same wheel load coverage. Cement
Research Institute of India (CRI) also demonstrated the use of SFRC in one of the jet bays at
Delhi airport. Other filed experiments in which SFRC has been used are the slabs of parking
garage at Heathrow airport in London, spillway deflectors in Sweden, mine cribbing in Utah,
USA.

SULPHUR IMPREGNATED CONCRETE

Sulphur, sand and coarse aggregate are the ingredients of this concrete. Molten sulphur is added
to the preheated aggregates in a mixture. The hot mix is immediately transferred into the moulds
to fill them completely. The products manufactured with sulphur concrete need no curing and the
moulds can be stripped immediately as the sulphur solidifies rapidly under normal temperatures.
One of the major advantages of these products is that they can be remoulded and concrete can be
reused with minimum or no wastage. These products have very low absorption and less
permeability.

Strength upto 44 MPa have been reported when 30 % of sulphur, 50% of sand and 20% of coarse
aggregate are mixed. These are therefore versatile for use as precast slab elements of canal and
tunnel linings.