Carbon fiber reinforced concrete (Carbocrete)

1. Presented to: Dr. Mohamed Nagib Abou-Zeid Carbocrete The American University In Cairo School Of Science And Engineering Department Of Construction and Architectural Engineering

2. What is Carbocrete ? History of carbon fibers Manufacturing of carbon fibers Carbon fibers in construction Carbon fibers vs. steel (Properties) Carbocrete Mixing Testing Key properties of Carbocrete Advantages & disadvantages Economic aspects Applications Conclusion References Outline

3. 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 ? Carbocrete http://www.haute-innovation.com

4. 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 Edison www.biography.com Filament en.wikipedia.org

5. 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 propeller pics1.this-pic.com

6. 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 PAN www.c-chem.co.jp

7. 1 st : in the thermoset treatment, the fibers are stretched and heated to no more than 400° C 2 nd : in the carbonize treatment, the fibers are heated to about 800° C in an oxygen free environment to remove non-carbon impurities. 3 rd : 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. 4 th : 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)

8. Manufacturing of Carbon Fibers (Cont’d) PAN Manufacturing Process www.arrhenius.ucsd.edu

9. 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

10. 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 Strengths www.innovationskraftwerk.de

11. Carbon Fibers vs. Steel (Cont’d) Comparison Between Carbon Fibers and Steel Fibers www.innovationskraftwerk.de

12. Carbocrete Mixing Method Methods: Dry mix Wet mix Mixing Methods http://wings.buffalo.edu

13. Carbocrete Mix Design Mix Design For different CF sizes http://wings.buffalo.edu

14. Compressive Strength Test Flexural Strength Test Slump Test Testing

15. Key Properties of Carbocrete Properties of Carbocete www.sglgroup.com

16. Advantages & Disadvantages Advantages Disadvantages High 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

17. Economic Aspects www.toray.com

18. Economic Aspects (Cont’d) www.utsi.edu

19. Applications Limited 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

20. Applications (Cont’d) Carbocrete Balcony www.sglgroup.com

21. Applications (Cont’d) Shore protection seashells www.sglgroup.com

22. Applications (Cont’d) Carbocrete bicycle stands www.sglgroup.com

23. Applications (Cont’d) Carbocrete Z-shell www.sglgroup.com

24. Applications (Cont’d) Carbocrete residential/office buildings www.sglgroup.com

25. Applications (Cont’d) Video: http://www.youtube.com/watch?v=Ux1yIpGO7p8

26. Conclusion Carbocrete 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

27. http://www.carbonwrapsolutions.com http:// www.toray.com http://www.biography.com http://www.sglgroup.com http://www.haute-innovation.com/de/vortraege-diskussionen/werkstoffe-fuer-nachhaltiges-bauen.html http://www.youtube.com/watch?v=Ux1yIpGO7p8 http://www.innovationskraftwerk.de/Wettbewerb/sgl/Carbon-Beton/Details/38 http://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

28. Thank you