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the ultimate reinforcement for concrete in challenging applications

research & testing

Pultron Composites would like to thank the following experts, companies and research institutions for their help in testing and developing mateenbarTM:

Professor Mohammad HarajliDepartment of Civil & Environmental EngineeringAmerican University of BeirutLebanon

Professor Mesfer M. Al-ZahraniDepartment of Civil EngineeringKing Fahad University of Petroleum & MineralsSaudi Arabia

Kevin SpooTanya RedfernOwens Corning

Professor Ayman MosallamCivil & Environmental EngineeringUniversity of California USA

Frank Alderton FIQ New Zealand

Standards Measurements LaboratoryIndustrial Research LtdNew Zealand

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technical characteristics

metric (mm) imperial 8 10 #3 12 #4 16 #5 20 #6 25 #8 32 38

diameter range: other sizes available on request

lengths: made to order, to minimise on-site installation time and material wastage.

shapes available: right angles angles stirrups links specialist shapes made to order

sizes & shapes

material property value imperial standard

tensile strength minimum * >1000 MPa ** 145 ksi ASTM D3916-84

modulus (tensile) typical * 54.5 GPa 7904 ksi ASTM D3916-84

minimum * >50 GPa 7250 ksi

shear strength (single sided) typical 260 MPa 37.7 ksi ASTM B769-94

minimum 230 MPa 33.4 ksi

shear strength (double sided) typical 520 MPa 75.4 ksi ASTM B769-94

minimim 460 MPa 66.7 ksi

compressive strength (longitudinal) typical 690 MPa 100 ksi ASTM D695

minimim 500 MPa 72.5 ksi

moisture absorption typical 0.024% BS2782 pt 4,method 430/ ISO 62-1980

thermal conductivity typical 0.25 W/mK-1 ASTM C117

electrical strength typical 5 - 40 kV/mm DIN 53 481

volume resistivity typical 1010Ω.m DIN 53 482

dielectric constant typical < 5 DIN 53 483

magnetic properties non-magnetic

density typical 1.9 - 2.1 g/cm3

* tensile strength and modulus are typically higher for smaller diameter bars** based on 20mm diameter

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mateenbar™

is the ideal product,

developed specifically

for engineers who

are working in

environments with

demands beyond the

abilities of (traditional)

steel reinforcement.

Traditionally, the preferred reinforcement system for concrete structures has been steel. However, steel has its limitations, making it unsuitable for certain environments and applications. In such conditions, design engineers have struggled to find a satisfactory material and often had to accept inadequate solutions.

For 25 years, Pultron Composites has been working closely with engineers to develop FRP reinforcement with high performance engineering properties, to solve problems beyond the abilities of steel.

In 1985, Pultron worked in conjunction with DuPont to develop a reinforcement system that addressed the shortfalls of steel. These were introduced to the coal mining industry to help improve mine safety in difficult geotechnical situations and also to increase productivity by eliminating the down-time previously caused by the use of steel reinforcements.

Since then, Pultron has worked with key market players, developing FRP reinforcement specific to their requirements. Ongoing R&D projects ensure that Pultron is at the leading edge of technology.

• Perfect for highly corrosive environments

• Non-conductive

• Non-magnetic

• Cutable

• Low carbon imprint

• Culmination of 20 years FRP reinforcement development

• Cost effective alternative to stainless steel

designed for performance™™

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resistance to corrosion & chemicalsmateenbar™ is highly resistant to chemical attack, so it does not rust. This makes it ideal for marine applications, chemical plants and other environments where steel is unsuitable. Design engineers working in such conditions select mateenbar™ to achieve acceptable life-spans. mateenbar™ is also the ideal material for applications where minimal concrete coverage may be required – since its corrosion resistance eliminates leaching of rust stains which otherwise ruin the surface aesthetics.

non-conductive & non-electro magneticDue to the non-electromagnetic and non-conductive properties, stray electrical currents do not cause induction in mateenbar™. Often, in areas of high electrical fields significant power is lost due to induction in the surrounding steel reinforcement. This creates a number of problems including: extensive earthing systems required for electrical safety; greater concrete coverage requirements for electrical insulation; accelerated corrosion of rebars due to high levels of electrolysis; as well as increased installation costs and time welding every joint.

In addition, a two-fold energy wastage problem is created by the presence of steel: induction losses create eddy currents which heat the reinforcement - so increased cooling is required to remove this unwanted heat.

advantages™™

low thermal conductivityThe excellent insulation properties of mateenbar™ help ensure that the concrete maintains a good thermal insulation value.

cutableIn tunnelling projects, Pultron mateenbar™ is specified for soft-eyes. The Tunnel Boring Machine (TBM) can cut through the soft eyes easily without risk of damage to expensive cutting equipment. The saving in down-time is also critical in helping engineers keep projects running on schedule.

non-magneticClose to magnetic apparatus - such as hospital MRI rooms, compass calibration areas and certain high-voltage applications - steel reinforcement is unsuitable because the magnetic properties interfere with sensitive equipment. These problems are avoidable by specifying mateenbar™ as the reinforcement for these applications.

minimum moisture absorptionMoisture absorption must be minimised to ensure longevity of composites. Our moisture absorption rates are extremely low, ensuring mechanical properties are maintained for as long as possible.

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bond strength testing of mateenbar™

microscopic view of mateenbar™

price/performance advantage

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tensile strengthGlass content, fibre straightness, and the bond between fibres and matrix are well controlled to ensure maximum tensile strength. The high tensile strength of mateenbar™ offers designers compara-tively higher factors of safety.

modulusThe modulus of mateenbar™ is almost at the theoretical limit for the material - meaning maximum benefit is achieved from the raw materials, ultimately offering designers a price/ performance advantage

bond strengthThe bond strength of mateenbar™ has been optimised to offer reinforcement suitable for most commercial strengths of concrete.

destructive tensile testing of mateenbar™

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price/performance advantage

cost advantageIn any application where corrosion resistance is paramount, mild steel is unsuitable. High-grade stainless steel or mateenbar™ may be considered suitable reinforcements. In such cases, a cost saving of 40% on reinforcement would be expected by specifying mateenbar™. Where coverage can be reduced by use of mateenbar™, the saving on concrete will also be considered favourable in a total system cost analysis.

life-spanmateenbar™ is formulated from some of the most highly corrosion resistant materials available. Precise process control ensures optimum performance is achieved from these materials for maximum durability. This is most critical in harsh environments where performance of other materials may prove inadequate.

materialsmateenbar™ is manufactured from a proven epoxy backboned resin system for maximised corrosion resistance and increased interlaminar shear strength. Carefully selected glass types are used to ensure immunity to alkaline attack.

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Laura School

Rita Elementary School

Rita Elementary School

College of Marshall Islands

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Marshall Islands

Pultron’s mateenbar™ was specified for a series of new school and college buildings built throughout the low-lying island chain of the Republic of the Marshall Islands. This eliminated steel corrosion problems, considerably extended the expected life-span, and gave reassurance to design and construction engineers as well as the owners of the new buildings. It also gave the children much needed improvements to their learning environment.

period

2004 - 2007

designer

Beca Carter Hollings & Ferner

construction

Pacific International

Anil Developments

projects

Laura School

Jaluit School

Rita Elementary School

Marshall Islands High School – Phase I

College of Marshall Islands Dormitory

College of Marshall Islands - Phase I

Namdrik Elementary School - Phase I

College of Marshall Islands - Phase II

Namdrik Elementary School – Phase II

Northern Islands High School – Phase I & II

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Eastlink tunnel

The mateenbar™ was used to create isolation breaks within the Springvale Road tunnel, on the new USD 2.0 billion “Eastlink M3” toll road in Melbourne, Australia.

If steel reinforcement is continuous throughout the length of a tunnel, eddy currents created by induction are sufficient to accelerate the rate of corrosion within the steel reinforcement. Solving this was traditionally costly: extra reinforcement was allowed for within the design to compensate for the accelerated corrosion; joints were welded to ensure electrical contact; and earthing systems were linked to sacrificial cathodic blocks. This was both time consuming and expensive.

The electrical insulation properties of mateenbar™ allowed the designers to isolate short sections of reinforcement - thereby reducing eddy currents and reducing the affects of accelerated corrosion, as well as saving both time and money on the project.

year

2007

project cost

USD 2.0 Billion

owner

ConnectEast Pty Ltd

designer

CW-DC Pty Ltd

construction

Thiess John Holland JV

CW-DC is a wholly owned subsidiary of Connell Wagner

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Isolation Joint200mm clear spacingrequired betweenlongitudinalsteel reinforcement

mateenbar™Lap Joints at isolation breaks.

year 2002

owner SMRT Trains Ltd

size 109km of lines

stations 64 currently operating (expansion in progress)

daily usage 1.654 million passengers

During the construction of the Singapore MRT underground stations, various concrete walls and columns had to be built in the path of the Tunnel Boring Machine (TBM) prior to tunnelling.

mateenbar™ was used for ‘soft-eyes’ within walls and ‘soft-column’ sections in positions where the TBM would be required to cut through during later stages of construction.

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Singapore MRT

Singapore MRT Station

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Muscat Expressway

Dubai Marina

Central Corridor Muscat Airport

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project year owner Main Contractor Consultant

Muscat Expressway under const. Muscat Municipality - Oman Galfar Engineering & Contracting Parsons

Shahama Saadiyat Freeway Package 1 under const. Aldar Six Construct Co. Ltd Halcrow

Central Corridor under const. Muscat Municipality - Oman Galfar Engineering & Contracting Parsons

Seeb International Airport 2007 Muscat Municipality - Oman Carillion Alawi LLC Parsons

Shahama Saadiyat Freeway Package 2A under const. Aldar Taisei Corporation Halcrow

Qatar Primary Rout North Road C2 & C3 under const. Qatar Petroleum Tekfen Construction & Installation INC Dar al-handasah

Mesaieed Bridges 2005 Qatar Petroleum ASKA Qatar Petroleum

EMAAR West side Marina Infrastructure Package 3D 2004 EMAAR Al Futtaim Carillion Hyder Consulting

3rd Bridge Crossing Abu Dhabi 2005 Abu Dhabi Public Works Dept Archirodon/Bin Hafeez Est. High-Point Rendel

King Abdul Aziz Interchanges Jn. 65A to Jn.14G 2006 Government of Sharjah Sharjah General Contracting Halcrow Int.

R659-2 Jumeirah Lake Interchanges 2007 RTA Dutco Balfour Beatty Parsons International Ltd.

Baharain Map I/C under const. Ministry of Works & Housing NASS Construction Co. W.L.L Parsons

EMAAR West side Marina Infrastructure Package 3B 2003 EMAAR Al Futtaim Tarmac Parsons International Ltd.

Mina Al Arab Phase I under const. RAKPROPERTIES Darwish Engineering Halcrow

Halul Island 2003 OXY Occidental Petroleum CBI/Archirodon Mott Macdonald Ltd

Al Hamra Village Development, RAK 2005 Private Stratcon Maunsell

Pultron has worked closely with major industry leaders within the region to gain a full understanding of the requirements and develop the perfect reinforcement for the harsh conditions.

In soil walls and highway barriers, high strength reinforcement is required - but steel is subject to accelerated corrosion due to the high salt levels within the soil. The high corrosion resistance of Pultron’s reinforcement has made it the ideal material for these applications.

Basements are often below the level of the water table. The harshest of artesian water in the region is termed sabkha and is very highly corrosive. Sabkha presents particular difficulties for engineers – with corrosion of steel reinforcement being a major problem. The excellent durability of mateenbar™ has made it the preferred choice of engineers in such applications.

mateenbar™ is also a superior and cost-effective alternative to stainless steel for the reinforcement of submerged sections of bridge footings in tidal zones and other structures subject to the salt-laden waters of the Gulf.

Middle East™™

Northside storage tunnel construction

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The Northside Storage Tunnel was built in Sydney, Australia (1998 – 2000) from the suburb of Lane Cove (Western Sydney) to North Head. The total tunnel length was in excess of 20km, with diameters from 3.8 metres to 6.6 metres, a total excavation of 750,000m3 of ground and a project cost of USD 400 million.

The tunnel was commissioned to collect storm overflows from the sewerage system to reduce contamination from raw sewage entering Sydney’s iconic harbour.

Due to the potentially corrosive nature of the chemicals present in the storm-water and sewage overflow, it was determined that stainless steel reinforcement could not offer the required life-span and that a more corrosion resistant material would be required.

Pultron worked in conjunction with the tunnel design engineers to develop specialised tunnel reinforcement rockbolts based on mateenbar™ which fulfilled the required mechanical properties and offered the extreme corrosion resistance requirements for this difficult application.

year

1998 – 2000project value

USD 400 million designer

Connell Wagnerconstruction

MWH, Transfieldowner

Sydney Water

Northside storage tunnel

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Tunnel Network

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year 1999 onwards

projects & applications Various cable stabilisation projects

design & installation Ocean Technix

Ocean Technix specialises in difficult un-dersea engineering projects. In the shallow reef waters of the Indian Ocean off the coast of Western Australia, divers had the task of stabilising sub-sea cables by drilling holes into hard rock areas of the sea bed and gluing rockbolts based on mateenbar™ in place with an epoxy resin system designed to cure under water. Neoprene straps were then used to secure the cable in place.

Stabilisation of sub-sea cables

underwater applications

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Research Publications & Reference Material

“Analysis of Aged Vinylester & Polyester Pultruded Composites”, Dr Salwan Al-Assafi, Composite Materials Research (* see note). Journal of Advanced Materials, approved for publication, December 2003

“Performance of Composites with Various Resin Systems in Aqueous Environ-ment”, Dr Salwan Al-Assafi, Composite Materials Research. Proceedings of first International Conference on Applications of Traditional and High Performance Materials in Harsh Environments, American University of Sharjah, UAE, 2004

“Impact of Aqueous Environments on Performance of Pultruded Composites”, Dr Salwan Al-Assafi, Composite Materials Research, A.Mosallam. Proceed-ings of the International Conference on Future Vision and Challenges for Urban Develop-ment, 2004

“Thermomechanical Analysis of Water Aged Pultruded Composites”, Dr Salwan Al-Assafi, Composite Materials Research. Proceedings of the fourth Asian-Australian Conference on Composite Materials, 2004

“ACI 440R-07 Report on Fiber-Reinforced Polymer (FRP) Reinforcement for Concrete Structures” – American Concrete Institute.

“ACI 440.3R-04 Guide Test Methods for Fibre Reinforced Polymers (FRP’s) for Reinforcing or Strengthening Concrete Structures” – American Concrete Institute.

* Composite Materials Research is a subsidiary of Pultron Composites Ltd.

Manufactured by:

Pultron Composites Ltd

PO Box 323, 342 Lytton RoadGisborne, New ZealandTel: +64 6 867 8582Fax: +64 6 867 8542Email: sales@pultron.com

Pultron Composites Middle East

PO Box 17522Jebel Ali Free Zone, DubaiUnited Arab EmiratesTel: +971 50 640 4345Fax: + 971 4 361 9675Email: pultronME@pultron.com

www.mateenbar.com www.pultron.com

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