Post on 28-Jan-2015
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Presented to: Dr. Mohamed Nagib Abou-Zeid
Carbocrete
The American University In CairoSchool Of Science And Engineering
Department Of Construction and Architectural Engineering
Aly Attia
Ihab Khalil
Fathy Abdel Halim
MohamedMubarak
What is Carbocrete?History of carbon fibersManufacturing of carbon fibersCarbon fibers in constructionCarbon fibers vs. steel (Properties)Carbocrete MixingTestingKey properties of CarbocreteAdvantages & disadvantagesEconomic aspectsApplicationsConclusionReferences
Outline
It is a type of concrete that is reinforced with carbon fibers so it’s also known as “Carbon Reinforced Concrete”.
It is a new highly stressable lightweight composite construction that combines special fine grain ultra high-strength concrete and carbon fibers.
It has higher strength than steel with quarter of its weight.
What is Carbocrete?
Carbocretehttp://www.haute-innovation.com
In late 1800s, Thomas Edison was the first to use carbon fibers as filaments for early light bulbs.
It lacked the high tensile strength of today’s carbon fibers; however he used it because of their high tolerance to heat which made these fibers ideal for conducting electricity.
History of Carbon Fibers
Thomas Edisonwww.biography.com
Filamenten.wikipedia.org
It wasn’t until the late 1950 that high-performance carbon fibers was manufactured by Mitsubishi Rayon
The USA’s Air Force and NASA didn’t wait develop the carbon fiber technology and began to use carbon fiber reinforced polymers to replace heavy metals to allow aircrafts to be lighter and faster.
History of Carbon Fibers (Cont’d)
Carbon fiber aircraft propellerpics1.this-pic.com
Manufacturing of Carbon Fibers
Raw carbon fiber is made from either polyacrylonitrile (PAN) or petroleum coal.
These fossil-fuel- based materials come from either petroleum refining or natural gas processing
Petroleum coal www.c-chem.co.jp
PANwww.c-chem.co.jp
1st: in the thermoset treatment, the fibers are stretched and heated to no more than 400° C
2nd: in the carbonize treatment, the fibers are heated to about 800° C in an oxygen free environment to remove non-carbon impurities.
3rd: fibers are graphitized; this step stretches the fibers between 50 to 100% elongation, and heats them to temperatures ranging from 1100° C to 3000° C. The stretching ensures a preferred crystalline texture, which results in the desired tensile strength.
4th: the last two treatment steps, surface treatment and epoxy sizing, are preformed to enhance the carbon fiber bonding strength.
Manufacturing of Carbon Fibers (Cont’d)
Carbon Fiber in Construction
Carbon fibers are mostly used for repair purposes of old structural element against shear and flexure failure; the material know as CFRP.
However, in the early 1990s, researches showed that carbon fibers can be used inside the concrete instead of steel reinforcement showing a significant improvement in the flexural and tensile strength of concrete.
http://www.carbonwrapsolutions.com
www.sglgroup.com
Carbon Fibers vs. Steel Up to 75% lighter More durable/corrosion-free 5 times higher tensile strength 2 times higher stiffness Higher temperature tolerance
Comparison of Fiber Strengthswww.innovationskraftwerk.de
Carbon Fibers vs. Steel (Cont’d)
Comparison Between Carbon Fibers and Steel Fibers
www.innovationskraftwerk.de
Advantages & Disadvantages
Advantages DisadvantagesHigh tensile strength:
Smaller cross-sections Earthquake resistance
Expensive: High initial cost
Higher durability: Corrosion-free Less running cost
Lack of knowledge: Absence of codes No implementations yet
Eco-friendly: Less materials needed for
maintenance and construction.
High thermal conductivity High HVAC consumption
Low weight: Easy to handle
Risk of lung cancer in the manufacturing phase
High flexibility: More creative architectural
design
High abrasion resistance: Suitable for highway
construction
Low coefficient of thermal expansion High fire resistance
ApplicationsLimited applications
In 2012, SGL Group launched a competition among innovative engineers to answer the question "What can I make from carbon concrete?„
A total of 319 ideas were submited
Applications (Cont’d)Video:
http://www.youtube.com/watch?v=Ux1yIpGO7p8
ConclusionCarbocrete pushed the limits of creativity and flexibility in
design
Made it possible to build unique structures that can withstand very high loads
Save maintenance costs on the long run
http://www.carbonwrapsolutions.comhttp://www.toray.comhttp://www.biography.comhttp://www.sglgroup.comhttp://www.haute-innovation.com/de/vortraege-diskussionen/werkstoffe-
fuer-nachhaltiges-bauen.htmlhttp://www.youtube.com/watch?v=Ux1yIpGO7p8http://www.innovationskraftwerk.de/Wettbewerb/sgl/Carbon-Beton/
Details/38http://wings.buffalo.edu/academic/department/eng/mae/cmrl/Concrete
%20reinforced%20with%20up%20to%20vol%20of%20short%20carbon%20fibers.pdf
http://www.utsi.edu/research/carbonfiber/cf.htm
References